Intrinsically safe sensor device for multi-parameter detection of oil

Abstract

The present invention relates to an intrinsically safe sensing device for oil multi-parameter detection, comprising an immersion sensor assembly and a control box assembly, wherein the immersion sensor assembly comprises a cylindrical shell, a strong magnetic abrasive adsorption head installed at the front end of the cylindrical shell, a ferromagnetic abrasive sensor and a dielectric sensor installed inside the cylindrical shell, and a temperature sensor surface-mounted on the cylindrical shell, wherein the interior of the immersion sensor assembly is integrally potted with a two-component potting glue, the cylindrical shell is made of insulating and waterproof material, the control box assembly comprises a control box, a circuit board is installed in the inner cavity of the control box, power supply cables and detection signal cables of the ferromagnetic abrasive sensor, dielectric sensor and temperature sensor are all connected to the circuit board, and the internal circuits of the control box and the immersion sensor assembly are all intrinsically safe circuits. The present invention can simultaneously detect three oil-related parameters of oil abrasive, oil temperature and dielectric, and save installation space.

Description

Technical Field

[0001] The invention relates to an oil multi-parameter detection device, in particular to a sensing device with intrinsic safety characteristics and suitable for multi-parameter measurement of oil inside mechanical transmission equipment in coal mines. Background Art

[0002] Coal mine underground mechanical equipment contains a large number of different types of mechanical transmission systems, such as the rocker arm and traction transmission box of the coal mining machine, the travel transmission box of the tunneling machine, etc. The health status of the gears, bearings and other components contained in these transmission boxes directly affects the normal operation of the entire mechanical system. In practical applications, the wear state of the transmission components can be determined by detecting the distribution and accumulation of abrasive particles in the lubricating oil inside the transmission box. The assembly and working state of the transmission system can be determined by detecting the temperature change of the lubricating oil. The dielectric parameters of the oil can be used as a basis for judging whether the oil is emulsified. The wear state of the transmission components, the assembly and working state of the transmission system, and the degree of emulsification of the oil all have an impact on whether the gears, bearings and other components are normal or not. Therefore, it is ideal to be able to detect the above parameters in a timely manner.

[0003] However, most traditional sensors can only detect a single parameter. If multi-parameter fusion testing is required, multiple independent sensors need to be arranged. Traditional oil wear particle detection sensors need to be arranged in the lubricating oil pumping pipeline, which is inconvenient to install and easily affects the normal operation of the entire lubrication circuit. When multiple independent sensors need to be arranged, it not only wastes space, but also increases the probability of failure.

[0004] In addition, general-purpose oil detection sensors are generally divided into two independent parts: the sensor probe and the back-end processing circuit; the two are connected by cables, which are greatly affected by electromagnetic interference and are easily damaged by equipment squeezing or falling coal blocks when used underground, so their reliability is not high.

[0005] When sensors are used in actual applications, due to differences in the structure and application environment characteristics of different installation locations, the requirements for sensor structure installation are also different, requiring structural customization and secondary design. Summary of the invention

[0006] In order to overcome the above-mentioned defects of the prior art, the present invention provides an intrinsically safe sensing device for multi-parameter detection of oil, which can simultaneously detect three oil-related parameters of oil abrasive particles, oil temperature and dielectric, and save installation space.

[0007] The main technical solutions of the present invention are:

[0008] An intrinsically safe sensing device for multi-parameter detection of oil, comprising an immersion sensor assembly and a control box assembly, the immersion sensor assembly comprising a cylindrical shell, a strong magnetic abrasive adsorption head installed at the front end of the cylindrical shell, a ferromagnetic abrasive sensor and a dielectric sensor body installed inside the cylindrical shell, a temperature sensor and a positive and negative electrodes of the dielectric sensor surface-mounted on the cylindrical shell, the interior of the immersion sensor assembly is integrally potted with a two-component potting glue, the cylindrical shell adopts an insulating waterproof material, the control box assembly comprises a control box, a circuit board is installed in the inner cavity of the control box, power supply cables and detection signal cables of the ferromagnetic abrasive sensor, the dielectric sensor and the temperature sensor are all connected to the circuit board, and the internal circuits of the control box and each sensor of the immersion sensor assembly are intrinsically safe circuits.

[0009] The strong magnetic abrasive adsorption head is a permanent magnet, and a ferrite protection ring is preferably installed on its outer ring.

[0010] The ferromagnetic wear particle sensor is preferably located at the core of the cylindrical housing, and the dielectric sensor is located at the rear of the cylindrical housing.

[0011] The cylindrical shell may be in the shape of a cylindrical cylinder.

[0012] The rear end of the immersion sensor assembly is fixedly connected to the control box assembly via a flange assembly, and the interior of the control box is completely insulated and potted with potting glue.

[0013] An external socket is arranged on the side wall of the control box. The external socket is provided with a cable connector for power supply and signal, and is respectively connected with the power input terminal and the signal output terminal of the circuit board.

[0014] The flange is provided with external threads, and the control box is provided with a plurality of countersunk screw holes, which do not penetrate the inner cavity of the control box.

[0015] The flange assembly comprises a flange and a sealing ring, and the sealing ring is sleeved on the flange.

[0016] The inner cavity of the control box is sealed with a mounting plate after potting, and the mounting plate is fixed on the control box.

[0017] The beneficial effects of the present invention are:

[0018] The present invention can simultaneously detect three oil-related parameters, namely, oil abrasive particles, oil temperature and dielectric. It has a high degree of integration, greatly saves installation space, and reduces the failure rate of the equipment under test due to the reduction of sensor installation points. Therefore, compared with the application method of multiple independent parameter sensors, it has obvious advantages in installation difficulty, failure rate and protection performance.

[0019] Since the outer ring of the strong magnetic abrasive adsorption head is installed with a ferrite epoxy protection ring, the ferromagnetic abrasive particles will only accumulate at the corresponding position in the front of the immersion sensor assembly, so it will not affect the measurement of the rear dielectric sensor and effectively reduce the interference of the strong magnetic abrasive adsorption head on the rear-end electrical signal.

[0020] Since the internal circuit of the sensor is an intrinsically safe circuit, the present invention has intrinsically safe electrical characteristics and can be directly used in an underground explosion environment of a coal mine.

[0021] The present invention is an integrated sensing device formed by fixing an immersion sensor assembly integrating multiple sensors and a control box assembly equipped with a back-end processing circuit through a flange assembly. The immersion sensor assembly and the control box are both sealed, so that the sensing device has excellent characteristics of shock resistance and waterproofness. The signal transmission between the two is realized inside the device, eliminating the physical damage and electromagnetic interference that may be caused to the external cables. Therefore, the working reliability is high and it can well adapt to the real-time monitoring of the health status of the oil in the transmission system of underground mechanical equipment such as coal mining.

[0022] The present invention has two installation and fixing methods: threaded installation on the outer surface of the fixing flange and screw installation and fixing on the control box assembly, which has wider adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention;

[0024] Figure 2 is a structural principle diagram of the immersion sensor assembly of the present invention;

[0025] Figure 3 It is a structural schematic diagram of the control box assembly of the present invention.

[0026] Figure numerals: 1—immersion sensor assembly, 10—cylindrical shell, 11—strong magnetic abrasive adsorption head, 12—ferromagnetic abrasive sensor, 13—dielectric sensor, 14—temperature sensor, 15—ferrite epoxy protection ring, 2—flange assembly, 21—flange, 22—sealing ring, 3—control box assembly, 31—control box, 32—screw, 33—external socket, 34—inner cavity of control box, 35—countersunk screw hole, 36—mounting plate. DETAILED DESCRIPTION

[0027] The present invention discloses an intrinsically safe sensor device (hereinafter referred to as a sensor device) for oil multi-parameter detection. Figure 1-3As shown, it includes an immersion sensor assembly 1 and a control box assembly 3. The immersion sensor assembly includes a cylindrical shell 10, a strong magnetic abrasive adsorption head 11 installed at the front end of the cylindrical shell, a ferromagnetic abrasive sensor 12 and a dielectric sensor 13 installed inside the cylindrical shell, and a temperature sensor 14 surface-mounted on the cylindrical shell. The dielectric sensor 13 body is installed inside the cylindrical shell, and its positive and negative poles are mounted on the outer surface of the cylindrical shell. The interior of the immersion sensor assembly is integrally potted with a two-component potting glue. The cylindrical shell adopts an insulating and waterproof material. During detection, the immersion sensor assembly is directly immersed in the oil as a whole. Through the strong magnetic abrasive adsorption head, the abrasive particles generated in the oil due to the wear of the transmission components are adsorbed to the front end of the probe. The control box assembly includes a control box 31, and the inner cavity 34 of the control box is installed with a circuit board (not shown in the figure). The power supply cables and detection signal cables of the ferromagnetic wear particle sensor, dielectric sensor and temperature sensor are all led out from the rear end of the cylindrical shell to the control box and connected to the circuit board. The internal circuits of the control box and each sensor of the immersion sensor assembly are intrinsically safe circuits, so that the sensor device can be directly used in the explosion environment of coal mines. The analog signals collected by each sensor are processed and converted by the corresponding processing circuit located on the circuit board, and then transmitted from the circuit board in the form of electrical signals.

[0028] The basic working principle of the ferromagnetic abrasive particle sensor is that the size and quantity of the ferromagnetic abrasive particles on the strong magnetic abrasive particle adsorption head are different, which will have different effects on the magnetic force, causing changes in the electrical parameters of the ferromagnetic abrasive particle sensor. By recording the induction signal generated by the ferromagnetic metal abrasive particles, the induction signal contains the characteristics and quantity information of the abrasive particles, so the size and quantity of the adsorbed abrasive particles can be judged based on the induction signal. The size and quantity of the abrasive particles, that is, the detection result of the ferromagnetic abrasive particle sensor, reflects the degree of wear of the transmission element. The larger the size and quantity of the abrasive particles, the more serious the wear of the transmission element.

[0029] When the oil is contaminated, its dielectric parameters and operating temperature will change. Therefore, by detecting the dielectric parameters through the dielectric sensor and the temperature parameters through the temperature sensor, the health status of the oil can be effectively judged. Based on the principle that different dielectric resistivities are different, the dielectric sensor can detect whether the oil is emulsified and the severity of the emulsification. The temperature sensor is used to quickly detect changes in oil temperature.

[0030] The sensing device of the present invention can be directly immersed in the oil to be tested, and can simultaneously detect three oil-related parameters: oil abrasive particles, oil temperature and dielectric. It can adapt to real-time monitoring of the health status of the oil in the transmission system of underground mechanical equipment such as coal mining, save installation space, and reduce the failure rate.

[0031] The size of the immersion sensor assembly can be customized and redesigned according to different application scenarios.

[0032] The strong magnetic abrasive adsorption head is a permanent magnet, which can be in the shape of a ring. The outer ring is preferably installed with a ferrite epoxy protection ring 15, so that the ferromagnetic abrasive particles will only accumulate at the corresponding position in the front of the immersion sensor assembly, and will not affect the measurement of the rear dielectric sensor, thereby effectively reducing the interference of the strong magnetic abrasive adsorption head on the rear-end electrical signal.

[0033] The ferromagnetic wear particle sensor is located at the core of the cylindrical shell, and the detection sensitive range is the front end of the cylindrical shell.

[0034] The dielectric sensor and the temperature sensor are located at the rear of the cylindrical housing.

[0035] The cylindrical shell is preferably in the shape of a cylindrical cylinder.

[0036] For any of the above-mentioned sensing devices, the rear end of the immersion sensor assembly is preferably fixedly connected to the control box assembly 3 through the flange assembly 2 to form an integrated sensing device. The internal space of the inner cavity 34 of the control box is completely insulated and potted with potting glue. The immersion sensor assembly and the back-end circuit are designed to be integrated, and the two are placed in the same structural module, eliminating the cable connection between the two, reducing or eliminating the interference of the external electromagnetic environment on the sensing device, and also avoiding the connection cable from being squeezed by the equipment or damaged by the coal blocks that fall off, so that the reliability of the sensing device is significantly improved.

[0037] An external socket 33 is provided on the side wall of the control box, and a cable connector for power supply and signal is arranged in the external socket, and is respectively connected to the power input terminal and signal output terminal of the circuit board. By providing an external socket, the reliability of the external electrical connection of the sensor device is improved compared with directly leading out the cable. After the plug and socket are installed, the connector assembly has high dust and water resistance as a whole, and the sensor detection signal can be transmitted reliably. The three sensors inside the immersion sensor assembly transmit the measured oil parameters to the circuit board in the control box assembly in the form of electrical signals, and the circuit board performs data preprocessing and signal conversion on it, and finally transmits the signal to the host computer via the external socket in the form of a bus.

[0038] The sensor device has two fixing methods. One fixing method is threaded connection and fixing. The flange is provided with an external thread. When in use, it is only necessary to arrange a threaded hole of corresponding size on the device under test, insert the immersion sensor assembly of the sensor device into the lubricating oil of the device under test, and directly screw and fix the sensor device on the device under test through the external thread. Another fixing method is screw fixing. The control box is provided with a plurality of countersunk screw holes 35. There are two in the embodiment shown in the attached figure. The countersunk screw holes and the inner cavity of the control box do not interfere with each other. When in use, the immersion sensor assembly of the sensor device is inserted into the lubricating oil of the device under test, and the control box is placed against the surface of the device under test. The screw 32 is inserted into the countersunk screw hole, and the screw 32 is fastened to the threaded hole of corresponding specifications pre-opened on the device under test, so that the sensor device is installed and fixed on the device under test. When in use, one fixing method can be selected or both can be used at the same time to strengthen the fixation.

[0039] The flange assembly 2 includes a flange 21 and a sealing ring 22, and the sealing ring is sleeved on the flange. The sealing ring ensures that the entire sensor device is reliably sealed with the device under test when assembled to the device under test. The axial position of the sealing ring is closer to the control box than the external thread on the flange. Regardless of which of the above fixing methods is adopted, the sealing ring plays a sealing role between the outer diameter surface of the flange and the corresponding hole of the device under test. The sealing ring can be an O-ring, and accordingly, a sealing ring groove for embedding the O-ring is provided on the radial outer surface of the flange to limit the axial position of the O-ring.

[0040] The inner cavity of the control box is sealed with a mounting plate 36 after potting, and the mounting plate is fixed on the control box.

Claims

1. An intrinsically safe sensor device for multi-parameter detection of oil, characterized in that: The invention comprises an immersion sensor assembly and a control box assembly, wherein the immersion sensor assembly comprises a cylindrical shell, a strong magnetic abrasive adsorption head installed at the front end of the cylindrical shell, a ferromagnetic abrasive sensor and a dielectric sensor body installed inside the cylindrical shell, a temperature sensor and a positive and negative electrodes of the dielectric sensor surface-mounted on the cylindrical shell, the interior of the immersion sensor assembly is integrally potted with a two-component potting glue, the cylindrical shell adopts an insulating and waterproof material, the control box assembly comprises a control box, a circuit board is installed in the inner cavity of the control box, power supply cables and detection signal cables of the ferromagnetic abrasive sensor, the dielectric sensor and the temperature sensor are all connected to the circuit board, the internal circuits of the control box and each sensor of the immersion sensor assembly are intrinsically safe circuits, the strong magnetic abrasive adsorption head is a permanent magnet, and a ferrite protection ring is installed on its outer ring, during detection, the immersion sensor assembly as a whole is directly immersed in the oil, and the abrasive particles in the oil are adsorbed to the front end of the probe through the strong magnetic abrasive adsorption head.

2. The intrinsically safe sensor device for oil multi-parameter detection according to claim 1, characterized in that: The ferromagnetic wear particle sensor is located at the core of the cylindrical shell, and the dielectric sensor is located at the rear of the cylindrical shell.

3. The intrinsically safe sensor device for oil multi-parameter detection according to claim 2, characterized in that: The cylindrical shell is cylindrical.

4. The intrinsically safe sensor device for oil multi-parameter detection according to claim 1, 2 or 3, characterized in that: The rear end of the immersion sensor assembly is fixedly connected to the control box assembly via a flange assembly, and the interior of the control box is completely insulated and potted with potting glue.

5. The intrinsically safe sensor device for oil multi-parameter detection according to claim 4, characterized in that: An external socket is arranged on the side wall of the control box. The external socket is provided with a cable connector for power supply and signal, and is respectively connected with the power input terminal and the signal output terminal of the circuit board.

6. The intrinsically safe sensor device for oil multi-parameter detection according to claim 4, characterized in that: The flange assembly includes a flange and a sealing ring nested on the outer diameter of the flange, the flange is provided with an external thread, the control box is provided with a plurality of countersunk screw holes, and the countersunk screw holes do not penetrate the inner cavity of the control box.

7. The intrinsically safe sensor device for oil multi-parameter detection according to claim 4, characterized in that: The inner cavity of the control box is sealed with a mounting plate after potting, and the mounting plate is fixed on the control box.

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