A system and method for online measurement of particle size in power oil

Abstract

This application proposes an online power oil particle size measurement system and method, comprising: a bypass detection component, which includes a detection bypass pipe, multiple detection elements disposed on the detection bypass pipe, and an oil mixing component; the inlet and outlet of the detection bypass pipe are connected to the main oil pipeline, and the oil to be tested is drawn from the main oil pipeline, passes through the detection bypass pipe into the detection elements for detection, and then flows back to the main oil pipeline; the system includes a purification pipe, a purification element disposed on the purification pipe, and a second particle size detection element, wherein the two ends of the purification pipe are respectively connected to the detection bypass pipe and the oil mixing component; the second particle size detection element is located between the purification element and the oil mixing component, and is used to detect the operating oil after passing through the purification element. This embodiment achieves online monitoring of the particle size of normally operating oil while also considering online monitoring of severely degraded oil, realizing the purpose of online non-destructive monitoring of the particle size of power oil of different qualities.

Description

Technical Field

[0001] This application relates to the field of power oil testing technology, and in particular to a system and method for online measurement of the particle size of power oil. Background Technology

[0002] Optical obscuration particle size analyzers are a primary method for particle size detection in power oils due to their advantages such as rapid measurement, accuracy, and online operation. The working principle of optical obscuration particle size analysis is as follows: the operating oil being tested flows through a particle size sensor at a constant flow rate under system pressure. When particles in the oil pass through the sample flow chamber within the sensor, they generate corresponding pulses and pulse intensities at a photodetector on one side of the flow chamber. By acquiring the number and intensity of pulses, the number and size distribution of particles in the tested operating oil can be obtained. This sensor is used for monitoring the particulate contamination level of operating oils because of its advantages of fast detection speed, high accuracy, good repeatability, and insensitivity to the conductivity of the liquid.

[0003] When using a photoresist particle size sensor, the accuracy of the detection results is significantly affected by the condition of the operating oil. For example, oil deterioration leading to darker color or emulsification reduces light transmittance, and excessively high oil viscosity prevents the required flow rate for particle size detection. These factors can severely impact the accuracy of the results, even causing serious distortion. Currently, particle size monitoring of operating oil relies on laboratory sample testing, requiring personnel to assess the oil's condition based on experience. For conditions affecting particle size detection accuracy, diluents must be added to ensure the oil meets the requirements for photoresist testing. However, diluted oil cannot be reused. Existing online particle size monitoring systems are only suitable for operating oils of relatively good quality; they cannot detect or monitor oils in poor condition.

[0004] For situations affecting the accuracy of particle size detection, power system oils must be sent to specialized oil testing laboratories. The oils must be diluted with a diluent before testing. While relevant standards stipulate that severely emulsified or excessively viscous operating oils require dilution with a suitable cleaning solution for particle size testing, they do not specify the amount, method of addition, or operating environment of the diluent. There are no unified standards for preparation accuracy and the uniformity of the prepared operating oil; generally, laboratory personnel prepare the solution based on their experience in a high-cleanliness cleanroom. Therefore, the accuracy of particle size detection obtained in the laboratory is affected by various factors. Furthermore, the power system oils monitored online ultimately flow back into the lubrication system, so the operating oil must not be contaminated. Existing online monitoring systems cannot achieve this goal and cannot perform online non-destructive monitoring of deteriorated operating oils. Summary of the Invention

[0005] This application aims to at least partially address one of the technical problems in the related art.

[0006] Therefore, the purpose of this application is to propose a system and method for online measurement of particle size of power oil, so as to realize online monitoring of the particle size of oil under normal operation while also taking into account the online monitoring of severely degraded oil quality, and to achieve the purpose of online non-destructive monitoring of particle size of power oil of different qualities.

[0007] To achieve the above objectives, this application proposes an online system for measuring the particle size of power oil, comprising:

[0008] A bypass detection assembly includes a bypass detection pipe, multiple detection elements mounted on the bypass detection pipe, and an oil mixing component. The inlet and outlet of the bypass detection pipe are connected to a main oil pipeline. Oil to be tested is drawn from the main oil pipeline, passes through the bypass detection pipe, enters the detection elements for detection, and then flows back to the main oil pipeline.

[0009] A purification assembly includes a purification pipeline, a purification element disposed on the purification pipeline, and a second particle size detection element. The two ends of the purification pipeline are respectively connected to the detection bypass pipeline and the oil mixing assembly. The second particle size detection element is located between the purification element and the oil mixing assembly and is used to detect the operating oil after passing through the purification element.

[0010] In some embodiments, the oil mixing assembly includes a mixing element and a plurality of inlets disposed on the mixing element; the plurality of inlets include at least a first oil inlet and a second oil inlet; the first oil inlet is connected to the detection bypass pipeline; and the second oil inlet is connected to the purification pipeline.

[0011] In some embodiments, the oil mixing assembly further includes a preheating element for heating the oil mixing assembly disposed therein to degas the operating oil passing through the oil mixing assembly.

[0012] In some embodiments, the mixing element is provided with a mixing chamber for containing operating oil and a stirring element that matches the mixing chamber and is located within the mixing chamber, so as to homogenize the operating oil in the mixing chamber by means of the stirring element.

[0013] In some embodiments, the output port of the mixer is connected to the detection bypass pipe, and the mixing chamber end of the output port is provided with a tapered structure.

[0014] In some embodiments, the agitator includes a plurality of spirally ascending blades, wherein the ratio of the pitch to the length of the mixing chamber is 1:20.

[0015] In some embodiments, the bypass detection assembly further includes a negative pressure maintaining element disposed on the detection bypass pipeline; depending on the direction of oil flow, the negative pressure maintaining element is located upstream of the oil mixing assembly and is used to degas the operating oil to prevent bubble generation.

[0016] In some embodiments, depending on the direction of oil flow, the plurality of detection elements include a viscosity sensor, a moisture sensor, a flow sensor, and a first particle size detector disposed on the detection bypass pipe and located downstream of the oil mixing assembly; wherein the detection element further includes a data processing module, wherein the data processing module is connected to the first particle size detector and the second particle size detector, respectively.

[0017] In some embodiments, a method for online measurement of the particle size of power oil is proposed, which utilizes the system described in any of the above embodiments to measure the particle size of power oil online, including the following steps:

[0018] The operating oil is pumped into the bypass pipeline. The first particle size analyzer determines whether the dynamic baseline voltage of the operating oil is below a set threshold. If not, the first particle size analyzer measures the operating oil online. If yes, the preheating unit and negative pressure maintenance unit are turned on, and the viscosity, moisture content, and flow rate of the operating oil are monitored using a viscosity sensor, a moisture sensor, and a flow sensor, respectively. Further, it is determined whether the viscosity, moisture content, and flow rate of the operating oil are within the set threshold range. If yes, the preheating unit and negative pressure maintenance unit are turned on, and the first particle size analyzer measures the operating oil online. If no, the operating oil is pumped into the purification pipeline and purified by the purification unit to obtain purified oil. The purified oil is then tested by the second particle size analyzer to ensure it meets the standard before entering the mixing unit through the second inlet. It is then mixed with the operating oil entering the mixing unit through the first inlet in the mixing chamber to obtain mixed oil. The mixed oil is then measured by the first particle size analyzer. When the mixed oil meets the set thresholds for viscosity, moisture content, and flow rate, particle size monitoring is performed according to this mixing ratio.

[0019] In some embodiments, the first particle size analyzer detects an initial baseline voltage of V0 for the operating oil that is below a set threshold V. t At that time, based on the difference ΔV1 between the mixed oil containing K1vol.% of the purified oil and the baseline voltage of the operating oil, the relationship between K1vol.% of the purified oil and ΔV1 is obtained as: (ΔV1 / K1vol.%)×R; where K1 is the initially set mixing ratio of the purified oil and the operating oil; ΔV1 is the difference between the mixed oil containing K1vol.% of the purified oil and the baseline voltage of the operating oil; and R is the correction coefficient between the actual adjustment ratio and the theoretical adjustment ratio.

[0020] The volume percentage of purified oil in the mixed oil is dynamically adjusted until the baseline voltage of the mixed oil is higher than the set threshold V. t That's it. The volume percentage of purified oil in the mixed oil is dynamically adjusted according to the purified oil dynamic adjustment ratio, which is obtained using the following formula:

[0021] Purified oil dynamic adjustment ratio K n =K n-1 +(V t -△V n-1 ) / (100△V n-1 / K n-1 )×R,

[0022] Where K n The mixing ratio of the nth purified oil and the operating oil, where n > 1; K n-1 The dynamic adjustment ratio of the purified oil in the previous test; V t The set threshold for the operating oil; △V n-1 For containing K n-1 vol.% is the difference between the purified oil mixture and the baseline voltage of the operating oil; R is the correction coefficient between the actual adjustment ratio and the theoretical adjustment ratio;

[0023] According to the magnitude K of a single adjustment n -K n-1 Not more than 20 vol.%; when K n -K n-1 When it is greater than 20 vol.%, according to K n =K n-1 Adjust the mixing ratio by adding +20 vol.%, and repeat this dynamic adjustment process until the baseline volt value of the mixed oil is higher than the set threshold V. t If K n If the final adjustment ratio is greater than 80 vol.%, it indicates that the volume percentage of purified oil is too high, the measured particle size data is not objective, or there is an anomaly in the system, and an early warning should be issued promptly. The particle size data of the mixed oil measured by the first particle size sensor is calculated according to the following formula:

[0024] c=(c(V A +V B )-c B V B ) / V A

[0025] c represents the number of particles within a certain size range in the operating oil, and c represents the number of particles within a certain size range in the mixed oil. B V represents the number of particles within a certain size range in the purified oil. A V represents the volume / mL of the monitored mixed oil sample. BThe volume of purified oil is expressed in mL.

[0026] Compared with the prior art, this application has the following beneficial technical effects:

[0027] This invention uses purified operating oil as a diluent. A precise metering pump is used to gradually mix the purified operating oil (used for dilution) and the operating oil to be tested according to a programmed algorithm. A microwave heating device and a negative pressure maintenance device are used to improve the state of the operating oil so that it meets the detection conditions of a photoresist particle size analyzer. The accurate particle size result of the operating oil is obtained by subtracting the number of particles from the diluted operating oil from the particle size monitoring results of the mixed operating oil. This avoids secondary pollution caused by operating oil contamination and achieves non-destructive online monitoring of operating oil particle size.

[0028] Furthermore, for non-uniformly dispersed flaky or irregularly shaped abrasive particles generated when the gearbox is abnormally worn or severely worn, the particle size monitoring results obtained by adjusting the different proportions of diluted operating oil and the operating oil to be tested within a range above the threshold can be fitted. This not only provides accurate information on these non-uniformly dispersed flaky and irregular particles in the operating oil, but also reflects the wear condition of the lubrication system from another perspective.

[0029] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0030] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0031] Figure 1 This is a schematic diagram of the structure of a system for online measurement of particle size of power oil according to an embodiment of this application;

[0032] Figure 2 This is a schematic diagram of the structure of a system for online measurement of particle size of power oil according to an embodiment of this application;

[0033] Figure 3 This is a schematic diagram of the structure of a system for online measurement of particle size of power oil according to an embodiment of this application;

[0034] Figure 4 This is a flowchart of a method for online measurement of particle size of power oil according to an embodiment of this application;

[0035] Figure 5 This is a schematic diagram of the structure of a hybrid component proposed in an embodiment of this application;

[0036] In the diagram, 1. Main oil pipeline; 2. Detection bypass pipeline; 3. First oil pump; 4. Return oil pipe; 5. First particle size sensor; 6. Viscosity sensor; 7. Moisture sensor; 8. Flow sensor; 9. Preheating component; 10. Negative pressure maintaining component; 11. Shut-off valve; 12. Second oil pump; 13. Purification component; 14. Second particle size sensor; 15. Mixing component; 16. Third oil pump; 17. Fourth oil pump; 18. Oil mixing assembly; 19. Data processing module; 20. First oil inlet; 21. Second oil inlet; 22. Output port. Detailed Implementation

[0037] Embodiments of this application are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application. Rather, embodiments of this application include all variations, modifications, and equivalents falling within the spirit and scope of the appended claims.

[0038] See Figure 1 This application discloses an online system for measuring the particle size of power oil, comprising a bypass detection component and a purification component. The bypass detection component includes a detection bypass pipe 2, multiple detection elements mounted on the detection bypass pipe 2, and an oil mixing component 18. Both ends of the detection bypass pipe 2 are connected to the main oil supply line 1 in the lubrication system, which transports the operating oil. Specifically, the detection bypass pipe 2 is a bypass oil supply pipe with both its input and output ends connected to the main oil supply line 1 in the lubrication system. It is used to pump the operating oil in the main oil supply line 1 through a first oil pump 3 mounted on the detection bypass pipe 2 and introduce it into the multiple detection elements mounted on the detection bypass pipe 2 for detection.

[0039] The purification component in this embodiment includes a purification pipeline, a purification element 13 disposed on the purification pipeline, and a second particle size detection element. The purification pipeline is a pipe with an input end and an output end. The input end of the purification pipeline is connected to a detection bypass pipeline 2. A shut-off valve 11 is installed at the input end of the purification pipeline, and opening the shut-off valve 11 allows the operating oil in the detection bypass pipeline 2 to flow into the purification pipeline. The purification element 13 is disposed on the purification pipeline to purify the operating oil flowing into the purification pipeline. For example, the purification element 13 contains filter and drying packing, has filtering and drying functions, and can improve the color of the operating oil to a certain extent. The operating oil, after its color is improved by the purification element 13, becomes purified oil. After being detected by the second particle size detection element, the purified oil enters the oil mixing component 18 through the output end of the purification pipeline. The second particle size detection element can be understood as a particle size sensor. Figure 1 As shown, the second particle size detection component is the second particle size sensor 14.

[0040] In this embodiment, a bypass detection component is connected to the main oil supply line 1 in the lubrication system. The bypass detection component measures the particle size of the power oil online. When the first particle size detector cannot effectively detect the power oil, a purification component connected to the bypass detection component is used to pump the operating oil in the bypass pipeline 2 into the purification pipeline through a second oil pump 12 installed on the purification pipeline for purification. The purified oil is used as a diluent for the operating oil in the bypass pipeline 2. Using a precise metering pump, the two are gradually mixed in proportion according to the program algorithm to generate a mixed operating oil. The particle size detection result of the operating oil to be tested is obtained by subtracting the particle size of the purified oil from the particle size monitoring result of the mixed operating oil. This avoids secondary pollution caused by the contamination of the operating oil and achieves non-destructive online monitoring of the particle size of the operating oil.

[0041] In some embodiments, the oil mixing assembly 18 includes a mixing element 15 and a plurality of inlets disposed on the mixing element 15; the plurality of inlets include at least a first oil inlet 20 and a second oil inlet 21; the first oil inlet 20 is connected to the detection bypass pipeline 2; and the second oil inlet 21 is connected to the purification pipeline.

[0042] Specifically, the oil mixing assembly 18 includes a mixing element 15, which is a device with multiple input terminals and one output terminal. The input terminals of the mixing element 15 are respectively connected to the detection bypass pipeline 2 and the purification pipeline. According to the flow direction of the operating oil in the detection bypass pipeline 2, the output terminal of the mixing element 15 is connected to the detection bypass pipeline 2 downstream of its input terminal.

[0043] Examples such as Figure 5 As shown, the mixing component 15 has two input terminals and one output port 22. The two input terminals are the first oil inlet 20 and the second oil inlet 21, respectively. The first oil inlet 20 is connected to the detection bypass pipeline 2, and the second oil inlet 21 is connected to the purification pipeline.

[0044] Furthermore, in some embodiments, the mixing component 15 is provided with a mixing chamber for containing the operating oil and a stirring component that matches and is located within the mixing chamber. The stirring component rotates and homogenizes the operating oil within the mixing chamber. In other words, the mixing component 15 is provided with a mixing chamber for containing the operating oil, and the first oil inlet 20 and the second oil inlet 21 are respectively connected to the mixing chamber. A stirring component matching the inner diameter of the mixing chamber is provided within the mixing chamber, and the stirring component rotates and homogenizes the operating oil within the mixing chamber. It is also known that a liquid pump is installed on the detection bypass pipe 2 and the purification pipe at the first oil inlet 20 and the second oil inlet 21, wherein, for example... Figure 3 As shown, the liquid pumps at the first oil inlet 20 and the second oil inlet 21 are the third oil pump 16 and the fourth oil pump 17, respectively.

[0045] For example, the mixing chamber is a hollow cylindrical structure with a total length of 300 in actual production. The diameters of the first oil inlet 20 and the second oil inlet 21 are the same, both being 5. In some embodiments, the stirring component can be understood as including a stirring paddle. The blades of the stirring paddle rise in a spiral shape, wherein the ratio of the pitch to the length of the mixing chamber is 1:20. When the total length of the mixing chamber is 300, the pitch of the spiral blades is 15.

[0046] In some embodiments, the diameter of the output port 22 on the mixing member 15 is 5; and the mixing chamber end of the output port 22 is provided to be tapered.

[0047] In this embodiment, the operating principle of the mixing component 15 is as follows: when the operating oil and the purified oil are introduced from the first oil inlet 20 and the second oil inlet 21, the stirring component is rotated at a corresponding speed according to the viscosity of the different operating oils, so that the operating oil and the purified oil can be quickly mixed to form a uniform mixture. At the same time, when the mixture leaves the mixing chamber through the outlet 22 of the mixing component 15 and enters the detection element, it rotates under the action of inertia, which in turn can drive the particles in the mixture to rotate.

[0048] After the mixing tube designed according to the above technical specifications uniformly mixes the oil, a suitable rotation speed is determined based on the flow rate of the mixture and the particle size. This allows the particles in the mixture to complete one full rotation within the distance between fully entering and leaving the photosensitive zone. The laser can also scan through most of the particle area. During the time the particles complete their rotation, the different areas of the particles block the laser, resulting in voltages of varying amplitudes in the output electrical signal. By selecting the maximum and minimum voltage values ​​during this period as indicators for measuring the particle size, and then analyzing these two voltage values, the irregular particle shape is equated to a standard spherical particle to determine its size. The particle size sensor with increased rotation speed of the stirring element can measure particle size more accurately than traditional particle size sensors.

[0049] In some embodiments, the oil mixing assembly 18 further includes a preheating element 9, which is used to heat the oil mixing assembly 18 disposed inside, thereby degassing the operating oil passing through the oil mixing assembly 18.

[0050] Specifically, the oil mixing assembly 18 also includes a preheating component 9, wherein the oil mixing assembly 18 is disposed in the preheating component 9 to degas the operating oil or the mixture of operating oil and purified oil passing through the oil mixing assembly 18.

[0051] Specifically, preheating component 9 is a device that uses microwave heating. It primarily employs microwave preheating for degassing to eliminate the influence of viscosity, air bubbles, and emulsification of the operating oil on the particle size monitoring of the measured operating oil. For example... Figure 2 As shown, the third oil pump 16, the fourth oil pump 17, and the mixing unit 15 can be microwave heated.

[0052] In some embodiments, the bypass detection assembly further includes a negative pressure maintaining member 10, wherein the negative pressure maintaining member 10 is disposed on the detection bypass pipeline 2; depending on the direction of oil flow, the negative pressure maintaining member 10 is located upstream of the oil mixing assembly 18 and is used to degas the oil to prevent the generation of bubbles.

[0053] Specifically, the bypass detection assembly also includes a negative pressure maintaining element 10, which is installed on the detection bypass pipeline 2 and is mainly used for negative pressure degassing to prevent the formation of bubbles in the operating oil. For example, Figure 2 and Figure 3 As shown, according to the direction of oil flow, the negative pressure maintaining component 10 is located upstream of the oil mixing component 18. In this embodiment, a negative pressure degassing method is introduced in conjunction with a microwave preheating degassing method to adjust the state of the operating oil to be monitored to a state suitable for online monitoring.

[0054] In some embodiments, depending on the direction of oil flow, the plurality of detection elements include a viscosity sensor 6, a moisture sensor 7, a flow sensor 8, and a first particle size detector arranged in sequence; wherein the viscosity sensor 6 is located downstream of the oil mixing assembly 18; wherein the detection elements further include a data processing module 19, wherein the data processing module 19 is connected to the first particle size detector and the second particle size detector respectively.

[0055] Specifically, the first particle size detection component can be understood as a particle size sensor, such as... Figure 1 As shown, the first particle size detection element is the first particle size sensor 5; according to the flow direction of the operating oil in the detection bypass pipeline 2, the negative pressure maintenance element 10, the oil mixing component 18, the viscosity sensor 6, the moisture sensor 7, the flow sensor 8, and the first particle size sensor 5 are arranged sequentially upstream and downstream. In this embodiment, the negative pressure maintenance element 10 and the preheating element 9 are first turned on, and the viscosity sensor 6, the moisture sensor 7, and the flow sensor 8 are used to detect the viscosity, moisture content, and flow rate of the operating oil, respectively, to determine whether the operating oil needs to be purified. When purification is not required, the oil can be returned to the main oil supply pipeline 1 through the return oil pipe 4 on the detection bypass pipeline 2; when purification is required, the operating oil is pumped into the purification element 13 through the detection bypass pipeline 2, and the second particle size sensor 14 only detects the particle size of the purified oil.

[0056] The detection element also includes a data processing module 19, which is connected to both the first particle size detection element and the second particle size detection element. The data processing module 19 can calculate the baseline voltage of the first particle size sensor 5 and the set threshold V. tThe difference between them is used to determine the relationship between adjusting the mixing ratio of purified oil and ΔV, thereby dynamically adjusting the mixing ratio of purified oil until the baseline voltage Vn of the mixed oil measured by the first particle size sensor 5 is greater than the set threshold V. t This indicates that the oil condition inside the particle size sensor can be used to monitor the particle size of the operating oil. It can obtain more objective and accurate information about these non-uniformly dispersed flaky and irregular particles in the operating oil to be tested, and can also reflect the wear of the lubrication system from the side.

[0057] In some embodiments, such as Figure 4 As shown, a method for online measurement of the particle size of power oil is proposed. The method utilizes the system in any of the above embodiments to measure the particle size of power oil online, and includes the following steps:

[0058] S1: Pump the operating oil into the detection bypass pipeline 2, and use the first particle size detector to determine whether the dynamic baseline voltage of the operating oil is lower than the set threshold; if not, use the first particle size detector to measure the operating oil online; if yes, turn on the preheating component 9 and the negative pressure maintenance component 10 respectively, and use the viscosity sensor 6, moisture sensor 7 and flow sensor 8 to monitor the viscosity, moisture content and flow rate of the operating oil respectively.

[0059] Specifically, the operating oil in the main oil supply line 1 of the lubrication system is pumped out through the first oil pump 3 installed on the bypass pipeline 2. The operating oil passes sequentially through the negative pressure maintaining component 10, the mixing component 15, the viscosity sensor 6, the moisture sensor 7, the flow sensor 8, and the first particle size detector. The first particle size detector on the bypass pipeline 2 is used to determine whether the dynamic baseline voltage of the operating oil is lower than a set threshold. If the dynamic baseline voltage of the operating oil measured by the first particle size detector is lower than the set threshold, it indicates that the state of the operating oil cannot be accurately monitored for particle size using the first particle size detector. Therefore, it is determined whether the dynamic baseline voltage of the operating oil is lower than the set threshold. If the result is no, the operating oil is measured online using the first particle size detector and then returned to the main oil supply line 1 through the return oil pipe 4 on the bypass pipeline 2. However, if the result is yes, the preheating component 9 and the negative pressure maintaining component 10 can be turned on respectively, and the viscosity, moisture content, and flow rate of the operating oil can be monitored using the viscosity sensor 6, the moisture sensor 7, and the flow sensor 8 respectively.

[0060] S2: Determine whether the viscosity, moisture content, and flow rate of the operating oil are within the set threshold range; if yes, turn on the preheating component 9 and the negative pressure maintaining component 10 respectively and use the first particle size detection component to measure the operating oil online; if no, pump the operating oil into the purification pipeline and purify it through the purification component 13 to obtain purified oil. After the purified oil passes through the second particle size detection component to be tested and meets the standard, it enters the mixing component 15 from the second oil inlet 21. It is mixed with the operating oil entering the mixing component 15 from the first oil inlet 20 in the mixing chamber to obtain mixed oil. The mixed oil is then measured by the first particle size detection component. When the mixed oil meets the set threshold of viscosity, moisture content, and flow rate, particle size monitoring is performed according to this mixing ratio.

[0061] Specifically, the negative pressure maintaining component 10 and the preheating component 9 are activated. The viscosity sensor 6, moisture sensor 7, and flow sensor 8 are used to detect the viscosity, moisture content, and flow rate of the operating oil, respectively, to determine whether the operating oil needs purification. If the viscosity, moisture content, and flow rate of the operating oil do not exceed the set threshold, then the operating oil to be tested does not need to be purified. The operating oil to be tested can be returned to the main oil supply pipeline 1 through the return oil pipe 4 on the detection bypass pipeline 2. When any one of the viscosity, moisture content, or flow rate exceeds the set threshold, purification is required. At this time, the operating oil to be tested is pumped into the purification component 13 through the detection bypass pipeline 2. After purification, purified oil is obtained. After the purified oil passes through the first particle size detector to ensure it meets the standard, it enters the mixing component 15 through the second oil inlet 21. It is mixed with the operating oil entering the mixing component 15 through the first oil inlet 20 in the mixing chamber to obtain mixed oil. The mixed oil is then measured through the first particle size detector.

[0062] This embodiment marks the first time that online non-destructive monitoring has been performed on severely degraded operating oil that cannot be routinely monitored. Simultaneously, this method can also be used for online monitoring of particle size in power supply oils in good condition. The deterioration of operating oil is not a change in a single indicator or state; increased viscosity, emulsification, and darkening of color are the result of multiple factors. This invention introduces microwave preheating degassing combined with negative pressure degassing to adjust the state of the operating oil to be monitored to a suitable condition for online monitoring. Furthermore, by using purified oil as a diluent and dynamically adjusting the ratio of purified oil to operating oil according to a program algorithm, the particle size monitoring of the purified oil is subtracted as background interference, thereby obtaining accurate and true results for the particle size of the operating oil without adversely affecting the lubrication system's operating oil.

[0063] In some embodiments, the initial baseline voltage value of the operating oil detected by the first particle size analyzer is V0, which is lower than a set threshold V. tWhen the mixing ratio of purified oil and operating oil is set to K1vol.% (the recommended initial mixing ratio K1 is 10vol.%), i.e., the volume coefficient K1 = 10vol.%, the baseline voltage V1 of the mixed oil containing K1vol.% purified oil is detected by the first particle size sensor as an increase of ΔV1 compared to the baseline voltage of the operating oil, i.e., ΔV1 = V1 - V0. From this, the difference between the baseline voltage V1 of the mixed oil containing K1vol.% purified oil and the baseline voltage V0 of the operating oil can be obtained, and the relationship between K1vol.% purified oil and ΔV1 can be obtained: (ΔV1 / K1vol.%) × R; where K1 is the initially set mixing ratio of purified oil and operating oil; ΔV1 is the difference between the baseline voltage of the mixed oil containing K1vol.% purified oil and the operating oil; and R is the correction coefficient between the actual adjustment ratio and the theoretical adjustment ratio.

[0064] The volume percentage of purified oil in the mixed oil is dynamically adjusted until the baseline voltage of the mixed oil is higher than V. t That's it. The volume percentage of purified oil in the mixed oil is dynamically adjusted according to the purified oil dynamic adjustment ratio, which is obtained using the following formula:

[0065] Purified oil dynamic adjustment ratio K n =K n-1 +(V t -△V n-1 ) / (100△V n-1 / K n-1 )×R,

[0066] Where K n K represents the mixing ratio of the nth purified oil and the operating oil, where n > 1; n-1 The dynamic adjustment ratio of the purified oil in the previous test; V t The set threshold for the operating oil; △V n-1 For containing K n-1 The difference between the vol.% of the purified oil mixture and the baseline voltage of the operating oil; R is the correction factor between the actual adjustment ratio and the theoretical adjustment ratio.

[0067] According to the magnitude K of a single adjustment n -K n-1 Not more than 20 vol.%; when K n -K n-1 When it is greater than 20 vol.%, according to K n =K n-1 Adjust the mixing ratio by adding +20 vol.%, and repeat this dynamic adjustment process until the baseline volt value of the mixed oil is higher than the set threshold V. t If K nIf the final adjustment ratio is greater than 80 vol.%, it indicates that the volume percentage of the purified oil is too high, the measured particle size data is not objective, or there is an anomaly in the system, and an early warning should be issued in a timely manner.

[0068] In this embodiment, the particle size data of the mixed oil measured by the first particle size sensor is calculated according to c = (c(V)). A +V B )-c B V B ) / V A The online monitoring results of the operating oil particle size are obtained by calculation, where c is the number of particles within a certain size range in the operating oil, c is the number of particles within a certain size range in the mixed oil, and c is the number of particles within a certain size range in the mixed oil. B V represents the number of particles within a certain size range in the purified oil. A V represents the volume / mL of the monitored mixed oil sample. B The volume of purified oil is expressed in mL.

[0069] For example, the second particle size analyzer detects that the initial baseline voltage value V0 of the operating oil is lower than a set threshold V. t At this time, the initial mixing ratio K1 is set to 10 vol.%, and the purified oil and operating oil are mixed. The difference between the baseline voltage value measured by the first sensor and the baseline voltage value of the operating oil is ΔV1. The correction coefficient R between the actual adjustment ratio and the theoretical adjustment ratio is set to 0.85, according to K2 = 10 vol.% + (V t The purification oil adjustment ratio is calculated as -△V1) / (100△V1 / 10vol.%)×0.85. At this time, K2=35vol.%. According to the principle that K1-K0 should not be greater than 20vol.%, the actual result of K2 is 10vol.%+20vol.%=30vol.%. After mixing the oil according to the purification oil ratio of 30vol.%, the baseline voltage of the mixed oil detected by the first particle size sensor 5 is still lower than the set threshold V. t Repeat the above calculation formula K3=K1+(V t -ΔV2) / (100ΔV2 / 30vol.%)×0.85, K3=36.5%, at this time the baseline volt-value of the mixed oil is higher than V t The particle size data of the mixed oil measured by the first particle size sensor are calculated according to c = (c(V)). A +V B )-c B V B ) / V A The online monitoring results of the operating oil particle size are obtained by calculation, where c is the number of particles within a certain size range in the operating oil, c is the number of particles within a certain size range in the mixed oil, and c is the number of particles within a certain size range in the mixed oil. B V represents the number of particles within a certain size range in the purified oil. AV represents the volume / mL of the monitored mixed oil sample. B The volume of purified oil is expressed in mL.

[0070] Meanwhile, for the non-uniformly dispersed flaky or irregularly shaped abrasive particles generated by abnormal or severe wear of the gearbox, data monitoring of particle size obtained by adjusting the ratio of purified oil and the operating oil to be tested above a threshold can provide more objective and accurate information on these non-uniformly dispersed flaky and irregular particles in the operating oil, and can also reflect the wear condition of the lubrication system from another perspective. The mixing ratio of the device is dynamically adjusted.

[0071] It should be noted that in the description of this application, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, in the description of this application, unless otherwise stated, "a plurality of" means two or more.

[0072] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the function involved, as will be understood by those skilled in the art to which embodiments of this application pertain.

[0073] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0074] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A system for online measurement of particle size in power-grade oil, characterized in that, include: A bypass detection assembly includes a detection bypass pipe, a plurality of detection elements disposed on the detection bypass pipe, and an oil-mixing assembly; The inlet and outlet of the bypass pipeline are both connected to the main oil pipeline. Oil to be tested is drawn from the main oil pipeline, passes through the bypass pipeline, enters the detection element for detection, and then flows back to the main oil pipeline. The detection element includes a first particle size detector, located downstream of the oil mixing assembly. The bypass detection assembly also includes a negative pressure maintaining element installed on the bypass pipeline. Depending on the direction of oil flow, the negative pressure maintaining element is located upstream of the oil mixing assembly and is used to degas the oil to prevent bubble formation. A preheating element for heating the oil mixing assembly disposed therein, so as to degas the operating oil passing through the oil mixing assembly; and A purification assembly includes a purification pipeline and a purification element and a second particle size detection element disposed on the purification pipeline, wherein the two ends of the purification pipeline are respectively connected to the detection bypass pipeline and the oil mixing assembly; the second particle size detection element is located upstream of the purification element and the oil mixing assembly, and is used to detect the operating oil after passing through the purification element. The first particle size analyzer detects an initial baseline voltage of V0 in the operating oil, which is lower than a set threshold V. t At that time, based on the difference ΔV1 between the initial baseline voltage of the mixed oil containing K1vol.% purified oil and the operating oil, the relationship between K1vol.% purified oil and ΔV1 is obtained as: (ΔV1 / K1vol.%) × R; where K1 is the initially set mixing ratio of purified oil and operating oil; ΔV1 is the difference between the initial baseline voltage of the mixed oil containing K1vol.% purified oil and the operating oil; and R is the correction coefficient between the actual adjustment ratio and the theoretical adjustment ratio. The volume percentage of purified oil in the mixed oil is dynamically adjusted according to the adjustment range K. n -K n-1 Not more than 20 vol.%, until the baseline volt value of the blended oil is higher than V. t The dynamic adjustment ratio of the purified oil is obtained through the following calculation formula: Purified oil dynamic adjustment ratio K n =K n-1 +(V t -△V n-1 ) / (100△V n-1 / K n-1 )×R, Where K n The mixing ratio of the nth purified oil and the operating oil, where n > 1; K n-1 The dynamic adjustment ratio of the purified oil in the previous test; V t The set threshold for the operating oil; △V n-1 For containing K n-1 vol.% is the difference between the initial baseline voltage of the purified oil mixture and the operating oil.

2. The system according to claim 1, characterized in that, The oil mixing assembly includes a mixing component and multiple inlets disposed on the mixing component; the multiple inlets include at least a first oil inlet and a second oil inlet; the first oil inlet is connected to the detection bypass pipeline; The second oil inlet is connected to the purification pipeline.

3. The system according to claim 2, characterized in that, The mixing component is provided with a mixing chamber for containing the operating oil and a stirring component that matches the mixing chamber and is located within the mixing chamber, so as to uniformly mix the operating oil in the mixing chamber through the stirring component.

4. The system according to claim 3, characterized in that, The output port of the mixing component is connected to the detection bypass pipe, and the mixing chamber end of the output port is provided with a conical structure.

5. The system according to claim 3, characterized in that, The agitator comprises multiple spirally ascending blades, wherein the ratio of the pitch to the length of the mixing chamber is 1:

20.

6. The system according to claim 3, characterized in that, Depending on the direction of oil flow, the plurality of detection elements further include a viscosity sensor, a moisture sensor, and a flow sensor disposed on the detection bypass pipe and located downstream of the oil mixing assembly; wherein the detection element further includes a data processing module, wherein the data processing module is connected to the first particle size detection element and the second particle size detection element respectively.

7. A method for online measurement of particle size in power oil, characterized in that, The online measurement of particle size of power oil using the system described in claim 6 includes the following steps: The operating oil is pumped into the bypass pipeline. The first particle size analyzer determines whether the dynamic baseline voltage of the operating oil is below a set threshold. If no, the first particle size analyzer measures the operating oil online. If yes, the preheating unit and negative pressure maintenance unit are turned on, and the viscosity, moisture content, and flow rate of the operating oil are monitored using a viscosity sensor, a moisture sensor, and a flow sensor, respectively. Further, it is determined whether the viscosity, moisture content, and flow rate of the operating oil are within the set threshold range. If yes, the preheating unit and negative pressure maintenance unit are turned on, and the first particle size analyzer measures the operating oil online. If no, the operating oil is pumped into the purification pipeline and purified by the purification unit to obtain purified oil. The purified oil is then tested by the second particle size analyzer to ensure it meets the standard before entering the mixing unit through the second inlet. It is then mixed with the operating oil entering the mixing unit through the first inlet in the mixing chamber to obtain mixed oil. The mixed oil is then measured by the first particle size analyzer. When the mixed oil meets the set thresholds for viscosity, moisture content, and flow rate, particle size monitoring is performed according to the mixing ratio of purified oil and operating oil in the mixed oil at this time.

8. The method according to claim 7, characterized in that, The particle size data of the mixed oil measured by the first particle size sensor is calculated according to the following formula: c=( (In) A +V B )-c B In B ) / V A c represents the number of particles per particle within a certain size range of the operating oil. c represents the number of particles within a certain size range in the mixed oil. B V represents the number of particles within a certain size range in the purified oil. A V represents the volume / mL of the mixed oil being monitored. B The volume of purified oil is expressed in mL.

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