A multi-channel electromagnetic structure abrasive detection sensor and its detection method

Abstract

The present invention belongs to the field of mechanical equipment condition monitoring, and particularly relates to a wear particle detection sensor with a multi-channel electromagnetic structure and a detection method thereof. The detection sensor includes a sensor housing assembly and a magnetic field circuit detection assembly; the sensor housing includes an outer shell, a first pipe joint, and a second pipe joint. A through hole is provided on the side surface of the outer shell, and the first pipe joint and the second pipe joint are respectively arranged at the through hole openings on both sides; the magnetic field circuit detection assembly is located inside the sensor and includes a first magnetic pole, a second magnetic pole, a first induction coil, a second induction coil, and an excitation coil; the first magnetic pole and the second magnetic pole are connected. The first pipe joint and the second pipe joint are threadedly connected to the two through ports of the outer shell. A first sealing rubber ring and a second sealing rubber ring are respectively arranged at the connection positions of the first magnetic pole and the second magnetic pole of the first pipe joint and the second pipe joint.

Description

Technical Field

[0001] The present invention belongs to the field of mechanical equipment condition monitoring, and particularly relates to a multi-channel electromagnetic structure abrasive particle detection sensor and a detection method thereof. Background Art

[0002] With the development of technology, the degree of industrialization of social production has been continuously strengthened, and industrial equipment is widely used, so the maintenance of equipment has become increasingly important. At present, mechanical equipment is developing towards the trends of rapidity, complexity, and large scale. Practical research shows that metal particles generated by equipment wear are an important cause of equipment damage.

[0003] The lubrication system is an essential part of large-scale mechanical equipment. In addition to having functions such as lubrication and cooling, it also carries rich information on mechanical wear. Abrasive particles are important information carriers of the wear state. Monitoring them can understand the operating conditions of the equipment, so as to evaluate the working conditions of the equipment and predict faults, etc. In addition, early fault prediction can be carried out to repair at the source specifically. In this way, the periodic inspection of the equipment, the replacement of components, the large amount of maintenance costs during the equipment repair process, and the economic losses caused by shutdowns can be reduced. Therefore, the oil monitoring technology is now attracting more and more attention and is a technology that is widely used and developing rapidly in mechanical equipment.

[0004] Although the online abrasive particle monitoring technology has made great progress in recent years, there are still many unsolved problems. In the magnetic induction sensor, the monitoring of oil abrasive particles is realized by using the ferromagnetic property of the abrasive particles. After the excitation coil is energized, a stable magnetic field is generated. When the abrasive particles in the oil pass through the magnetic field, a voltage signal will be generated in the induction coil of the sensor, so as to achieve the purpose of oil monitoring. In actual situations, the different positions of the abrasive particles passing through the magnetic field result in differences in the output abrasive particle signals, which is not conducive to the analysis of oil abrasive particles. Summary of the Invention

[0005] Based on the problems existing in the prior art, the purpose of the present invention is to provide a multi-channel electromagnetic structure abrasive particle detection sensor and a detection method thereof, which can well ensure the reliability and accuracy of the monitoring sensor by setting channels at different positions in the magnetic field for monitoring and analysis.

[0006] In the first aspect of the present invention, the present invention provides a wear particle detection sensor with a multi-channel electromagnetic structure. The wear particle detection sensor includes a sensor housing structure and a magnetic field circuit detection component. The sensor housing structure includes an outer shell 1, a first pipe joint 41, and a second pipe joint 42. A protrusion is installed on a certain surface of the outer shell 1 for placing a wire joint 2. Through holes are provided on the other two surfaces of the outer shell 1 to penetrate these two surfaces. Threads are respectively provided at the ports of the first pipe joint 41 and the second pipe joint 42, and they are connected to the through holes of the outer shell 1 through the threads. The magnetic field circuit detection component is located inside the sensor housing structure, and the magnetic field circuit detection component includes a first magnetic pole 61, a second magnetic pole 62, a plurality of first induction coils 71, a plurality of second induction coils 72, and an excitation coil 3. The first magnetic pole 61 and the second magnetic pole 62 are symmetrically arranged facing each other with the perpendicular bisector of the outer shell (1) as the axis. A plurality of first induction coils 71 and a plurality of second induction coils 72 are installed in the corresponding first magnetic pole 61 and second magnetic pole 62.

[0007] Further, both the first magnetic pole 61 and the second magnetic pole 62 include an outer ring groove structure and a plurality of through hole structures inside. And the two ring groove structures face each other. Among them, the through holes of the first magnetic pole 61 and the through holes of the second magnetic pole 62 correspond one by one.

[0008] Further, there is an air gap with a thickness of 0.1 - 3 mm between the first magnetic pole 61 and the second magnetic pole 62.

[0009] Further, among the plurality of through hole structures inside the first magnetic pole 61 and the second magnetic pole 62, one through hole is located at the center of the first magnetic pole 61 and the second magnetic pole 62, and the rest of the through holes are evenly distributed around this through hole. The through hole located at the center of the first magnetic pole 61 and the second magnetic pole 62 is filled with an insulating non-ferromagnetic material.

[0010] Further, the shapes of the first magnetic pole 61 and the second magnetic pole 62 are N (N≥3) prisms or cylinders.

[0011] Further, corresponding first sealing rubber rings 51 and second sealing rubber rings 52 are provided on the opposite sides of the first magnetic pole 61 and the second magnetic pole 62, and they are connected to the corresponding first pipe joint 41 and second pipe joint 42 through the first sealing rubber rings 51 and second sealing rubber rings 52.

[0012] In the second aspect of the present invention, the present invention also provides a detection method for a wear particle detection sensor with a multi-channel electromagnetic structure, including the above-mentioned wear particle detection sensor with a multi-channel electromagnetic structure, and the method includes the following steps:

[0013] The exciting coil 3 in the oil detection sensor is supplied with direct current or high-frequency alternating current as the exciting current source; among them, high-frequency alternating current in the range of 10 kHz - 5 MHz can be selected as the excitation.

[0014] When there are abrasive particles passing through the abrasive particle detection sensor, the induced voltage data passing through different first induction coils 71 and different second induction coils 72 are demodulated to obtain the amplitude and phase corresponding to each group of first induction coils 71 and second induction coils 72.

[0015] According to the amplitude and phase obtained from different grouped induction coils, the size and material of the abrasive particles passing through the abrasive particle detection sensor are determined.

[0016] Among them, the magnetic field generated by the exciting coil 3 and the space between the first induction coil 71 and the second induction coil 72 is the air gap. The magnetic fluxes at different positions in the magnetic field are different. When the same abrasive particle passes through different channels, the changes generated are also different. Therefore, this characteristic can be used to detect the abrasive particle signals at different positions.

[0017] The present invention sets a magnetic field inside the sensor through the exciting coil and the air gap structure, conducts multi-channel comparison tests on magnetic poles, and fills the middle channel with an insulating non-ferromagnetic material for comparison with the middle pipeline. When metal abrasive particles pass through the sensor, the voltage at both ends of the induction coil is used to judge the characteristics of the abrasive particles according to the change in magnetic flux.

[0018] The present invention has the following advantages:

[0019] (1) Compared with traditional sensors, the structure is compact and the manufacturing difficulty is greatly reduced.

[0020] (2) The structure of the outer shell can effectively avoid external electromagnetic interference and is applicable to various environments.

[0021] (3) The detection ability for non-ferromagnetic particles with small magnetic permeability is further improved.

[0022] (4) The change in magnetic flux caused by the abrasive particles passing through the sensor is more obvious under the air gap structure design. Description of the Drawings

[0023] Figure 1 It is a cross-sectional view of a multi-channel electromagnetic structure sensor of the present invention;

[0024] Figure 2 It is an exploded schematic view of a multi-channel electromagnetic structure sensor of the present invention;

[0025] Among them, 1. Outer shell, 2. Wire joint, 3. Excitation coil, 41. First pipe joint, 42. Second pipe joint, 51. First sealing rubber ring, 52. Second sealing rubber ring, 61. First magnetic pole, 62. Second magnetic pole, 71. First induction coil, 72. Second induction coil. Specific implementation mode

[0026] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0027] As Figure 1 And Figure 2 Shown, this embodiment proposes a wear particle detection sensor with a multi-channel electromagnetic structure. The wear particle detection sensor includes a sensor housing structure and a magnetic field circuit detection component; the sensor housing structure includes an outer shell 1, a first pipe joint 41, and a second pipe joint 42. A protrusion is installed on a certain surface of the outer shell 1 for placing the wire joint 2; through holes penetrating the two surfaces are provided on the other two surfaces of the outer shell 1. Threads are provided at the ports of the first pipe joint 41 and the second pipe joint 42 and are connected to the through holes of the outer shell 1 through the threads; the magnetic field circuit detection component is located inside the sensor housing structure, and the magnetic field circuit detection component includes a first magnetic pole 61, a second magnetic pole 62, a plurality of first induction coils 71, a plurality of second induction coils 72, and an excitation coil 3; the first magnetic pole 61 and the second magnetic pole 62 are symmetrically arranged facing each other with the perpendicular bisector of the outer shell (1) as the axis; a plurality of first induction coils 71 and a plurality of second induction coils 72 are installed in the corresponding first magnetic pole 61 and second magnetic pole 62.

[0028] This embodiment further describes the above sensor.

[0029] Furthermore, both the first magnetic pole 61 and the second magnetic pole 62 include an outer ring groove structure and a plurality of through hole structures inside, and the two ring groove structures face each other. Among them, the through holes of the first magnetic pole 61 and the through holes of the second magnetic pole 62 correspond one by one. The ring groove structure is used to place the excitation coil 3, and the through holes are used to place the induction coils, namely the first induction coil 71 and the second induction coil 72.

[0030] Furthermore, there is an air gap with a thickness of 0.1 - 3 mm between the first magnetic pole 61 and the second magnetic pole 62.

[0031] Furthermore, the shapes of the first magnetic pole 61 and the second magnetic pole 62 are N (N≥3) prism or cylinder.

[0032] Further, corresponding first sealing rubber rings 51 and second sealing rubber rings 52 are arranged on the opposite sides of the first magnetic pole 61 and the second magnetic pole 62, and are connected to the corresponding first pipe joint 41 and second pipe joint 42 through the first sealing rubber rings 51 and the second sealing rubber rings 52.

[0033] Further, among the multiple through-hole structures inside the first magnetic pole 61 and the second magnetic pole 62, one through-hole is located at the exact center of the first magnetic pole 61 and the second magnetic pole 62, and the remaining through-holes are evenly distributed around this through-hole; the through-hole located at the exact center of the first magnetic pole 61 and the second magnetic pole 62 is filled with an insulating non-ferromagnetic material.

[0034] Since the channel corresponding to the through-hole at the exact center is filled with an insulating non-ferromagnetic material, therefore, the magnetic field signal passing through this channel is used as a magnetic field signal reference. The differences between the magnetic field signals generated by the channels corresponding to other different through-holes and this reference magnetic field signal can be obtained in advance. For example, assume that the first magnetic pole 61 and the second magnetic pole 62 each have N through-holes, and a set of first induction coils 71 and second induction coils 72 are arranged in each through-hole. Each set corresponds to one channel, and a total of N channels are corresponding; it is known that the magnetic field signal generated by the abrasive particle passing through the through-hole at the exact center is A1, and the magnetic field signals generated by the abrasive particle passing through the remaining channels are A2, A3,..., AN; through analysis, the differences between the magnetic field signals of each remaining channel and the through-hole at the exact center can be obtained, and then the differences in the abrasive particle signals output due to the abrasive particle passing through different channel positions of the magnetic field can be obtained; in the detection of unknown abrasive particle signals, based on this differential performance, the abrasive particle signals generated by the unknown abrasive particle when passing through the corresponding channels can be accurately obtained, and then the size and material of the abrasive particle can be determined through analysis of this abrasive particle signal.

[0035] Embodiment 2

[0036] The present invention provides a detection method for an abrasive particle detection sensor with a multi-channel electromagnetic structure, which is characterized in that it includes any one of the above-mentioned abrasive particle detection sensors with a multi-channel electromagnetic structure, and includes the following steps:

[0037] Apply direct current or high-frequency alternating current to the excitation coil 3 in the oil fluid detection sensor as the excitation current source; among them, high-frequency alternating current in the range of 10 kHz - 5 MHz can be selected as the excitation.

[0038] When there are abrasive particles passing through the abrasive particle detection sensor, demodulate the induction voltage data passing through different first induction coils 71 and different second induction coils 72 to obtain the amplitude and phase corresponding to each set of first induction coils 71 and second induction coils 72;

[0039] In an embodiment of the present invention, the collected induced voltage data can be amplified by a preamplifier, and the amplified signal is denoised by a band-pass filter. The denoised signal and a reference signal with the same frequency as the collected induced voltage data are put into a synchronous demodulator, and then through a postamplifier, and finally input into a processor to obtain the demodulated information data, that is, the amplitude and phase corresponding to the induced voltage after the abrasive particle passes through the first induction coil 71 and the second induction coil 72.

[0040] According to the amplitude and phase obtained from different grouped induction coils, determine the size and material of the abrasive particle passing through the abrasive particle detection sensor.

[0041] It can be understood that when the excitation coil 3 is energized with direct current or high-frequency alternating current as excitation, a magnetic field will be generated. When an abrasive particle passes through the magnetic field, the magnetic field changes, and a corresponding induced voltage will be generated. The characteristics of the abrasive particle can be demodulated and analyzed according to the corresponding induced voltage. There is a comparison for the induced voltage of each material, and different induced voltages can reflect the material of the abrasive particle passing through the sensor. The present invention does not specifically limit the specific demodulation and analysis process. Those skilled in the art can, based on the prior art, obtain the size and material of the abrasive particle passing through the abrasive particle detection sensor according to the corresponding induced voltage.

[0042] The present invention sets a magnetic field inside the sensor through the excitation coil and the air-gap structure, and conducts multi-channel comparison tests on the magnetic poles, with the middle pipeline as the comparison. When a metal abrasive particle passes through the sensor, the voltage at both ends of the induction coil is used to judge the characteristics of the abrasive particle according to the change of the magnetic flux. The present invention has the following advantages:

[0043] (1) Compared with traditional sensors, the structure is compact, and the manufacturing difficulty is greatly reduced.

[0044] (2) The structure of the external housing can effectively avoid external electromagnetic interference and is applicable to various environments.

[0045] (3) The detection ability for non-ferromagnetic particles with a small magnetic permeability is further improved.

[0046] (4) The change in magnetic flux caused by the abrasive particle passing through the sensor is more obvious under the design of the air-gap structure.

[0047] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "coaxial", "bottom", "one end", "top", "middle", "the other end", "upper", "one side", "top", "inner", "outer", "front", "center", "both ends", etc. is the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present invention.

[0048] In the present invention, unless otherwise clearly specified or limited, terms such as "install", "set", "connect", "fix", "rotate" shall be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated; it may be a mechanical connection or an electrical connection; it may be directly connected or indirectly connected through an intermediate medium, and it may be the communication inside two elements or the interaction relationship between two elements. Unless otherwise clearly limited, for those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood 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 wear particle detection sensor with a multi-channel electromagnetic structure, the wear particle detection sensor comprising a sensor housing structure and a magnetic field circuit detection component; characterized in that, The sensor housing structure includes a housing (1), a first pipe joint (41), and a second pipe joint (42). A protrusion is installed on a certain surface of the housing (1) for placing a wire joint (2). Through holes penetrating the two surfaces are provided on the other two surfaces of the housing (1). Threads are respectively provided at the ports of the first pipe joint (41) and the second pipe joint (42), and they are connected to the through holes of the housing (1) through the threads. The magnetic field circuit detection component is located inside the sensor housing structure, and the magnetic field circuit detection component includes a first magnetic pole (61), a second magnetic pole (62), a plurality of first induction coils (71), a plurality of second induction coils (72), and an excitation coil (3). There is an air gap between the first induction coil (71) and the second induction coil (72). The first magnetic pole (61) and the second magnetic pole (62) are symmetrically arranged facing each other with respect to the perpendicular bisector of the housing (1). A plurality of first induction coils (71) and a plurality of second induction coils (72) are installed in the corresponding first magnetic pole (61) and second magnetic pole (62). Both the first magnetic pole (61) and the second magnetic pole (62) include an outer ring groove structure and a plurality of through hole structures inside. The two ring groove structures face each other. Among them, the through holes of the first magnetic pole (61) and the through holes of the second magnetic pole (62) correspond one by one. Among the plurality of through hole structures inside the first magnetic pole (61) and the second magnetic pole (62), one through hole is located at the center of the first magnetic pole (61) and the second magnetic pole (62), and the remaining through holes are evenly distributed around this through hole. The first induction coil (71) and the second induction coil (72) are respectively placed in each through hole inside the corresponding first magnetic pole (61) and second magnetic pole (62). The excitation coil (3) is respectively wound in the ring groove structures of the first magnetic pole (61) and the second magnetic pole (62).

2. The abrasive particle detection sensor with a multi-channel electromagnetic structure according to claim 1, characterized in that, There is an air gap with a thickness of 0.1 - 3 mm between the first magnetic pole (61) and the second magnetic pole (62).

3. The abrasive particle detection sensor with a multi-channel electromagnetic structure according to claim 2, characterized in that, The through hole located at the center of the first magnetic pole (61) and the second magnetic pole (62) is filled with an insulating non-ferromagnetic material.

4. The abrasive particle detection sensor with a multi-channel electromagnetic structure according to claim 2, characterized in that, The materials of both the first magnetic pole (61) and the second magnetic pole (62) are ferrite.

5. The abrasive particle detection sensor with a multi-channel electromagnetic structure according to claim 4, characterized in that, The shapes of the first magnetic pole (61) and the second magnetic pole (62) are N (N≥3) - prism or cylinder.

6. The abrasive particle detection sensor with a multi-channel electromagnetic structure according to claim 1, characterized in that, Corresponding first sealing rubber rings (51) and second sealing rubber rings (52) are provided on the opposite sides of the first magnetic pole (61) and the second magnetic pole (62), and they are connected to the corresponding first pipe joint (41) and second pipe joint (42) through the first sealing rubber ring (51) and the second sealing rubber ring (52).

7. A detection method for a wear particle detection sensor with a multi-channel electromagnetic structure, characterized in that, It includes a wear particle detection sensor with a multi - channel electromagnetic structure as described in any one of claims 1 - 6. The detection method includes the following steps: Apply direct current or high - frequency alternating current to the excitation coil (3) in the oil - liquid detection sensor as the excitation current source; When there are abrasive grains passing through the abrasive grain detection sensor, the induction voltage data passing through different first induction coils (71) and different second induction coils (72) are demodulated to obtain the amplitude and phase corresponding to each group of the first induction coils (71) and the second induction coils (72). According to the amplitude and phase obtained from different grouped induction coils, the size and material of the abrasive grains passing through the abrasive grain detection sensor are determined.

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