Dual-function large-scale gearbox gear abrasion scrap iron particle monitoring transmitter

Abstract

The invention discloses a dual-function large gearbox gear wear scrap iron particle monitoring transmitter which comprises a monitoring module and a transmitting module, the monitoring module comprises a sensor probe and an installed magnet, and is provided with a sensor plate, a Hall magnetic sensing element and a temperature platinum resistor, and the transmitting module comprises a shell. A conditioning circuit board is arranged in an inner cavity of the shell. The invention relates to the technical field of scrap iron monitoring. According to the dual-function large-scale gearbox gear abrasion scrap iron particle monitoring transmitter, when fallen scrap iron is adsorbed through the sensor, the magnetic quantity of the sensor changes slightly, the transmitting module conducts conditioning according to a change signal of the sensor and converts the change signal into a digital signal or an analog signal, and then the signal value is output to an acquisition end; and through an area algorithm averaging mode, the current condition of the scrap iron content of the gear box can be observed in real time, and the running health state is monitored in real time.

Description

Technical Field

[0001] The invention relates to the technical field of iron chip monitoring, in particular to a dual-function transmitter for monitoring iron chip particles of gear wear in a large-scale transmission case. Background Art

[0002] Large industrial gearboxes generate relative extrusion motion during the gear meshing process during operation. As time goes by, changes in the gear meshing clearance will cause different conditions of gear meshing wear and extrusion. Although there is lubricating oil as an auxiliary agent in the gearbox, the gears will also be compressed to produce extruded iron chips falling, and severe cases will cause large pieces of tooth breakage and falling. As time goes by, the deterioration of the lubricating oil in the gearbox and the amount of extruded iron chips will directly affect the subsequent operating life of the gearbox. However, how to monitor the content of extruded iron chips in the gearbox in real time during continuous operation is particularly important. Therefore, the present invention introduces a measurement scheme that can monitor the iron chip content in the gearbox in real time and issue an alarm. Summary of the Invention

[0003] In response to the shortcomings of the existing technology, the present invention provides a dual-function large-scale gearbox gear wear iron chip particle monitoring transmitter, which solves the problem of how to monitor the content of iron chips squeezed and dropped in the gearbox in real time during continuous operation.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solutions: a dual-function large-scale gearbox gear wear iron chip particle monitoring transmitter, including a monitoring module and a transmitting module, the monitoring module including a sensor probe, the front end of the sensor probe is threadedly mounted with a magnet through a magnet cover ring, the inner cavity of the sensor probe is fixedly mounted with a sensor board through a lower circuit positioning block and an upper circuit positioning block, and a Hall magnetic sensing element is provided at one end and the middle part of the sensor board, the surface of the sensor probe is fixedly mounted with an annular magnetic ring through a first isolation retaining ring and a second isolation retaining ring, the surface of the sensor probe is sleeved with a limit ring, and the limit ring abuts against the second isolation retaining ring, the inner cavity of the sensor probe is fixedly mounted with a temperature platinum resistor, and the surface of the sensor board is provided with a silicone wire.

[0005] The transmitter module includes a shell, a mounting joint is threadedly sleeved on the shell, an O-ring is arranged between the shell and the mounting joint, and a conditioning circuit board is arranged in the inner cavity of the shell.

[0006] Preferably, the device further includes a connecting rod, and both ends of the connecting rod are respectively threadedly sleeved on the internal threads of the magnet and the mounting joint.

[0007] Preferably, the inner cavity of the connecting rod is provided with a wire hole for connecting the silicone wire and the temperature platinum resistor wire, and the silicone wire and the temperature platinum resistor pass through the wire hole and are electrically connected to the conditioning circuit board.

[0008] Preferably, the conditioning circuit board is fixedly mounted on the mounting joint by screws.

[0009] Preferably, the Hall magnetic sensing element is fixedly mounted on the bottom of the sensor probe.

[0010] Preferably, a connector is embedded in one end of the housing, and the conditioning circuit board is electrically connected to the connector via a wire.

[0011] The present invention provides a dual-function transmitter for monitoring iron chip particles in large-scale gearboxes. Compared with the existing technology, it has the following advantages:

[0012] 1. This dual-function large gearbox gear wear iron chip particle monitoring transmitter has a compact and small-volume structure design and does not occupy equipment operating space.

[0013] 2. This dual-function large gearbox gear wear iron chip particle monitoring transmitter has a strong adaptability of monitoring module unit, is easy to install and disassemble and maintain, and can be applied to gearboxes of different sizes.

[0014] 3. This dual-function large gearbox gear wear iron chip particle monitoring transmitter can replace the gearbox drain plug or oil inlet plug, and can be used as a plug and also for monitoring.

[0015] 4. This dual-function large gearbox gear wear iron chip particle monitoring transmitter has dual-function monitoring. It can monitor the content of iron chips falling to help judge the maintenance decision of the gearbox, and it can also monitor the oil temperature in the gearbox to help judge whether abnormal high temperature occurs.

[0016] 5. The dual-function large gearbox gear wear iron chip particle monitoring transmitter has a non-magnetic stainless steel exterior structure, which will neither affect the measurement of magnetic products nor cause rust due to working conditions.

[0017] 6. This dual-function large gearbox gear wear iron chip particle monitoring transmitter has various signal output forms, and the transmission module can be changed according to the needs of the on-site working conditions.

[0018] 7. This dual-function large gearbox gear wear iron chip particle monitoring transmitter has a flexible process connection form. It can flexibly change the thread specifications of the process connection according to the size and depth of the gearbox and change the connecting rod length according to the depth. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 It is a schematic diagram of the structure of the present invention;

[0020] Figure 2 The structure of the present invention Figure 1 A partial enlarged schematic diagram of point A in the middle.

[0021] In the figure: 1. Magnet; 2. Magnet cover ring; 3. Sensor probe; 4. Circuit lower positioning block; 5. Sensor board; 6. First isolation ring; 7. Annular magnetic ring; 8. Second isolation ring; 9. Limiting ring; 10. Circuit upper positioning block; 11. Connecting rod; 12. Temperature platinum resistor; 13. Silicone wire; 14. Mounting connector; 15. O-ring; 16. Housing; 17. Screw; 18. Conditioning circuit board; 19. Connector. DETAILED DESCRIPTION

[0022] The technical solutions in the embodiments of the present invention are clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0023] See also Figure 1-2 , an embodiment of the present invention provides a technical solution: a dual-function large-scale gearbox gear wear iron chip particle monitoring transmitter, comprising a monitoring module and a transmission module;

[0024] The first is the monitoring module. The monitoring module is a sensor module that can measure the temperature of the lubricating oil and the amount of iron chips adsorption. The sensor probe 3 is a part with a blind hole deep hole structure. The front end magnet 1 is threadedly fixed to the external thread of the sensor probe 3 through the magnet cover ring 2. The cavity inside the sensor probe 3 is plugged into the sensor plate 5. One end and the middle part of the sensor plate 5 are designed with Hall magnetic sensing elements. The end Hall magnetic sensing element is placed at the bottom of the sensor probe 3 to sense the magnetic changes of the magnet 1. The two Hall magnetic sensing elements evenly distributed in the middle correspond to the positions of the annular magnetic rings 7 respectively, which are used to monitor the changes in the magnetic field of the two evenly distributed annular magnetic rings 7. The annular magnetic ring 7 is arranged according to the design size position through the first isolation retaining ring 6 and the second isolation retaining ring 8. After installation and positioning, the positioning is completed through the limit ring 9 after accurate positioning, and the limit ring 9 is fixed by welding; the sensor board 5 is positioned and installed by the circuit lower positioning block 4 and the circuit upper positioning block 10, and is inserted into the hole of the sensor probe 3. After determining the installation position, glue is applied to fix it; then the temperature platinum resistor 12 is inserted into the hole of the sensor probe 3, and the sensor board 5 and the temperature platinum resistor 12 are encapsulated in the sensor probe 3 through the glue filling process; the connecting rod 11 is screwed on the internal thread of the sensor probe 3 in the form of a thread for positioning and fixing, and at the same time, the silicone wire 13 of the sensor board 5 and the wire of the temperature platinum resistor 12 are led out through the hole of the connecting rod 11 into the transmitter module and connected to the conditioning circuit board 18, and fixed and sealed with the sensor probe 3 by welding;

[0025] The lower circuit positioning block 4 and the upper circuit positioning block 10 are made of nylon.

[0026] The second is the transmitter module, which conditions, amplifies, and converts the signal transmitted by the first sensor module into an analog or digital signal. The transmitter module's conditioning circuit board 18 is secured to the mounting connector 14 by screws 17. The conditioning circuit board 18 is connected to the connector 19 via wires. The housing 16 is threaded onto the mounting connector 14 and sealed with an O-ring 15.

[0027] The sensing module and the transmitting module are connected via an intermediate connecting rod 11 , and both ends of the connecting rod are welded to the end of the sensor probe 3 and the mounting joint 14 respectively, thereby meeting the sealing requirements and preventing leakage.

[0028] Lubricating oil temperature and iron chip adsorption monitoring sensor working process

[0029] Installation preparation and deployment

[0030] Select the installation method: Depending on the gearbox type (vertical or horizontal), install the sensor on the gearbox wall, ensuring that the sensing area of the sensor module (magnet 1 area) is close to the bottom of the gearbox to capture settling or flowing iron chips.

[0031] Fixing the sensor module: Fix the sensor probe 3 to the gearbox through its mounting structure (such as thread or flange) so that its internal cavity is immersed in lubricating oil.

[0032] Fixing the transmitter module: Install the transmitter module (housing 16) outside the gearbox in a location that is convenient for wiring and maintenance.

[0033] Connection and sealing:

[0034] One end of the connecting rod 11 is firmly connected to the end of the sensor probe 3 by welding and sealed.

[0035] The other end of the connecting rod 11 is firmly connected and sealed to the mounting joint 14 of the transmitter module by welding. This welding connection forms a sealed channel to prevent lubricating oil leakage while allowing the sensor wire to pass through.

[0036] Iron filings adsorption and physical signal generation

[0037] Iron chips generation: During the operation of the gearbox, gear meshing, bearing wear, etc. generate metal wear particles (iron chips).

[0038] Chip conveying: Chips are carried by the flowing lubricating oil.

[0039] Iron chip adsorption: When lubricating oil containing iron chips flows through the magnet 1 at the front end of the sensor module (threadedly fixed to the sensor probe 3 through the magnet cover ring 2), the ferromagnetic particles are adsorbed and gathered on the surface of the magnet 1.

[0040] Magnetic field change: The adsorption of iron filings changes the distribution and intensity of the magnetic field around magnet 1.

[0041] Temperature conduction: The lubricating oil flows through the sensor probe 3, and its temperature directly acts on the temperature platinum resistor 12 inside the probe.

[0042] Sensor module signal perception

[0043] Iron chip signal sensing (Hall element):

[0044] The Hall effect magnetic sensing element at the upper end of the sensor plate 5 (located at the bottom of the sensor probe 3 ) senses in real time the tiny magnetic field changes generated by the magnet 1 due to the adsorption of iron filings.

[0045] The two Hall magnetic sensing elements in the middle of the sensor board 5 respectively monitor the magnetic field of the internal annular magnetic ring 7 (positioned by the first isolation retaining ring 6 and the second isolation retaining ring 8 and fixed by the limit ring 9) (as a reference or auxiliary measurement).

[0046] These Hall elements convert the changes in the sensed magnetic field strength into weak electrical signals (voltage / current changes).

[0047] Temperature signal sensing (platinum resistance):

[0048] The resistance value of the temperature platinum resistor 12 changes linearly with the change of the lubricating oil temperature.

[0049] This change in resistance can be converted into an electrical signal by a measuring circuit.

[0050] Signal transmission to the transmitter module

[0051] The Hall effect signal (representing the change in magnetic field caused by the iron filings) generated by the sensor board 5 is transmitted through its silicone wire 13 .

[0052] The temperature electrical signal (representing resistance change) generated by the temperature platinum resistor 12 is transmitted through its wires.

[0053] The two sets of wires pass through the hole inside the sealed connecting rod 11 together.

[0054] The wires enter the transmitter module and are ultimately connected to corresponding interfaces on the conditioning circuit board 18 .

[0055] Transmitter module signal conditioning and conversion

[0056] The conditioning circuit board 18 (fixed to the mounting connector 14 by screws 17 ) receives the raw electrical signal from the sensor module.

[0057] Iron filings signal processing:

[0058] Amplification: The weak Hall signal is amplified to a suitable level for processing.

[0059] Filtering: Filtering is performed to remove environmental and circuit noise interference.

[0060] Algorithm processing and conversion: The "area algorithm average" method (which may involve signal integration or specific time-window average calculation) is applied to process the signal to improve stability. The processed signal is converted by an analog-to-digital converter (ADC) into a digital value representing the iron filings adsorption amount, or conditioned into a standard analog signal (such as 4 - 20 mA).

[0061] Temperature signal processing:

[0062] Generally, a constant current source or a bridge circuit is used to convert the resistance change of the platinum resistor into a voltage change.

[0063] This voltage signal is amplified.

[0064] It is converted into a digital quantity by an ADC or conditioned into a standard analog signal (such as 4 - 20 mA).

[0065] Output preparation: The processed iron filings content signal and lubricating oil temperature signal are converted into selected standard output signals.

[0066] Signal output and transmission

[0067] The conditioning circuit board 18 outputs the processed standard signal through the connector 19.

[0068] Output mode selection (configured according to working conditions):

[0069] RS485 digital signal: Used for industrial bus networks, wired connection to PLC / DCS, etc.

[0070] Bluetooth signal: Used for short-distance wireless transmission to mobile devices (mobile phones / tablets).

[0071] Wireless remote transmission output: (such as LoRa, NB-IoT, 4G / 5G) for remote data transmission to the cloud platform / monitoring center.

[0072] Analog signal output: (such as 4 - 20 mA, 0 - 10 V) general industrial signal, connecting to display instruments or acquisition cards.

[0073] Data acquisition, transmission and monitoring

[0074] Acquisition: The output signal is received by corresponding acquisition end devices (such as PLC, RTU, gateway, wireless receiver, display instrument).

[0075] Transmission: The collected data (iron filings content, temperature) is sent to the monitoring platform (such as SCADA, cloud platform, equipment health management system) via a wired network or a wireless network (if the output or collection end supports it).

[0076] Monitoring and Analysis:

[0077] The monitoring platform displays the lubricating oil temperature and iron filings content (numerical value, trend chart, status indication) in real time for setting.

[0078] Alarm threshold: When the iron filings content increases abnormally or the temperature exceeds the standard, an alarm is automatically triggered to indicate potential faults (abnormal wear, lubrication failure).

[0079] Trend analysis is carried out based on historical data to support predictive maintenance decisions.

[0080] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or also includes elements inherent to such process, method, article or device.

[0081] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A dual-function large-scale gearbox gear wear iron chip particle monitoring transmitter, including a monitoring module and a transmission module, characterized by: The monitoring module comprises a sensor probe (3), the front end of the sensor probe (3) is threadedly mounted with a magnet (1) through a magnet cover ring (2), the inner cavity of the sensor probe (3) is fixedly mounted with a sensor plate (5) through a circuit lower positioning block (4) and a circuit upper positioning block (10), and a Hall magnetic sensing element is provided at one end and a middle portion of the sensor plate (5), the surface of the sensor probe (3) is fixedly mounted with an annular magnetic ring (7) through a first isolation retaining ring (6) and a second isolation retaining ring (8), the surface of the sensor probe (3) is sleeved with a limit ring (9), and the limit ring (9) abuts against the second isolation retaining ring (8), the inner cavity of the sensor probe (3) is fixedly mounted with a temperature platinum resistor (12), and the surface of the sensor plate (5) is provided with a silicone wire (13); The transmitter module comprises a housing (16), a mounting joint (14) is threadedly sleeved on the housing (16), an O-ring (15) is provided between the housing (16) and the mounting joint (14), and a conditioning circuit board (18) is provided in the inner cavity of the housing (16).

2. The monitoring transmitter for wear iron filings of a dual-functional large-scale gearbox gear according to claim 1, characterized in that: The device further comprises a connecting rod (11), and both ends of the connecting rod (11) are respectively threadedly sleeved on the internal threads of the magnet (1) and the mounting joint (14).

3. The monitoring transmitter for wear iron filings particles of a dual-functional large-scale gearbox according to claim 2, characterized in that: The inner cavity of the connecting rod (11) is provided with a wire hole for connecting the silicone wire (13) and the temperature platinum resistor (12). The silicone wire (13) and the temperature platinum resistor (12) pass through the wire hole and are electrically connected to the conditioning circuit board (18).

4. A dual-functional large-scale gearbox gear wear iron filings particle monitoring transmitter according to claim 1, characterized in that: The conditioning circuit board (18) is fixedly mounted on the mounting joint (14) by means of screws (17).

5. A dual-functional large-scale gearbox gear wear iron filings particle monitoring transmitter according to claim 1, characterized in that: The Hall magnetic sensing element is fixedly mounted on the bottom of the sensor probe (3).

6. The monitoring transmitter for wear iron filings of a dual-functional large-scale gearbox gear according to claim 1, characterized in that: A connector (19) is embedded in one end of the housing (16), and the conditioning circuit board (18) is electrically connected to the connector (19) via a wire.

Images