A device and method for distinguishing aliased metal abrasive particles based on variable frequency detection technology

Abstract

The present invention provides a device and method for distinguishing aliased metal abrasive particles based on variable frequency detection technology. The device of the present invention includes a sensor detection circuit, a variable frequency excitation circuit, and a data acquisition circuit; the variable frequency excitation circuit is used to provide excitation signals of different frequencies to the sensor detection circuit, so that the magnetic field strength of the coil continuously changes, thereby generating magnetic fields of different strengths; the sensor detection circuit generates an alternating magnetic field through the excitation signal applied by the variable frequency excitation circuit, and generates magnetic field changes of different strengths according to the change of the excitation signal, magnetizing the metal particles through the magnetic field; the data acquisition circuit is used to collect the inductance signal caused by the passage of metal particles, and process the inductance signal. The method of the present invention uses variable frequency excitation to explore the response relationship between the inductance effect and eddy current effect of tiny abrasive particles and the excitation frequency, so as to achieve the distinction between single iron particles, single copper particles, and aggregated metal particles of different materials.

Description

Technical Field

[0001] The present invention relates to the field of abrasive particle detection technology, and more specifically, to a device and method for distinguishing aliased metal abrasive particles based on variable frequency detection technology. Background Art

[0002] With the development of machining and manufacturing, the detection of metal abrasive particles has attracted increasing attention. Abrasive particles are tiny metal particles produced during mechanical grinding, typically ranging in size from a few microns to hundreds of microns. The presence of abrasive particles has a significant impact on the performance and lifespan of mechanical equipment. Therefore, the detection and classification of abrasive particles is particularly important.

[0003] Traditional wear particle detection methods primarily include optical microscopy and scanning electron microscopy. While these methods can accurately detect and analyze metal wear particles, they suffer from low resolution, slow detection speed, and unsuitability for online detection. In recent years, the sensitivity of wear particle detection sensors has greatly improved, but research on multi-particle discrimination detection still has certain limitations. Many studies have only summarized the superposition characteristics of multiple particles. When two particles pass together, the output signal only changes in amplitude, not shape, making it impossible to determine the shape of the output signal. This is especially true when ferromagnetic and non-ferromagnetic particles overlap. Since these two materials interact differently with the magnetic field, the magnetic field changes caused by their simultaneous passage through the sensor cancel each other out, resulting in inaccurate detection results. Summary of the Invention

[0004] In response to the aforementioned technical issues surrounding the inability of existing technologies to accurately detect and distinguish aliased metal particles in oil, a device and method for distinguishing aliased metal abrasive particles based on variable frequency detection technology are provided. By integrating the relationship between metal abrasive particles and sensor excitation frequency, this invention proposes a method for distinguishing aliased signals based on variable frequency detection. This method can detect the accumulation of particles with different properties, effectively addressing the limitations of traditional methods and improving the accuracy and efficiency of abrasive particle detection.

[0005] The technical means adopted in the present invention are as follows:

[0006] A device for distinguishing aliased metal abrasive particles based on variable frequency detection technology includes: a sensor detection circuit, a variable frequency excitation circuit, and a data acquisition circuit; wherein:

[0007] The variable frequency excitation circuit is used to provide excitation signals of different frequencies to the sensor detection circuit, so that the magnetic field strength of the coil continuously changes, thereby generating magnetic fields of different strengths;

[0008] The sensor detection circuit generates an alternating magnetic field through the excitation signal applied by the variable frequency excitation circuit, and generates magnetic field changes of different intensities according to changes in the excitation signal, thereby magnetizing the metal particles through the magnetic field;

[0009] The data acquisition circuit is used to collect the inductance signal caused by the passing of metal particles and process the inductance signal.

[0010] Furthermore, the variable frequency excitation circuit includes a signal source, a regulator, and a feedback circuit; wherein:

[0011] The signal source generates a stable voltage or current signal for stimulating the sensor detection circuit;

[0012] The regulator is used to adjust the gain, offset or conversion of the signal as needed to adapt to different application scenarios;

[0013] The feedback circuit makes the signal output by the amplifier stable, accurate and automatically calibrated through feedback control.

[0014] Furthermore, the sensor detection circuit includes an inductive detection chip and metal particles, wherein:

[0015] The inductive detection chip includes a glass substrate and a sensor module disposed on the glass substrate; the sensor module includes a microchannel, a metal particle inlet and a metal particle outlet respectively provided at both ends of the microchannel, and a coil wound around the microchannel, wherein both ends of the coil are respectively connected to the variable frequency excitation circuit;

[0016] The metal particles are metal abrasive particles generated by bearing wear and gearbox wear in various mining machines, ships, and offshore wind power machinery and equipment. The metal abrasive particles are distributed throughout the lubricating oil and hydraulic oil of the entire mechanical system and flow with the oil. The size and material of the metal abrasive particles are important criteria for judging equipment wear.

[0017] Furthermore, the data acquisition circuit includes an amplifier, a filter, an A / D converter and a processor, wherein:

[0018] The amplifier is connected to the inductive detection chip and is used to amplify the weak signal output by the inductive detection chip to a measurable or processable range;

[0019] The filter removes noise and interference from the output signal of the inductive detection chip to improve signal quality;

[0020] The A / D converter is used to convert analog signals into digital signals for digital processing and storage;

[0021] The processor is used to process, calculate and control digital signals.

[0022] The present invention also provides a method for distinguishing aliased metal abrasive particles based on the above-mentioned aliased metal abrasive particle distinguishing device and frequency conversion detection technology, comprising:

[0023] The variable frequency excitation circuit is used to perform multiple excitations on the coil in the sensor detection circuit, thereby changing the eddy current effect intensity of the metal particles. The data acquisition circuit is used to collect the output signal of the sensor module in the sensor detection circuit, thereby achieving the distinction between single iron particles, single copper particles, and aggregated metal particles of different materials.

[0024] Furthermore, the differentiation of single iron particles, single copper particles, and aggregated metal particles of different materials specifically includes:

[0025] The inductance signal of the iron particles does not change significantly with the excitation frequency, and the smaller the particles, the smaller the effect of the excitation frequency on the output signal;

[0026] The inductance signal output by the copper particles is greatly affected by the excitation frequency. When the excitation frequency is low-frequency excitation, the inductance change generated by the copper particles passing through the sensor module is less than the instrument's detection limit. When the excitation frequency is high-frequency excitation, the signal changes significantly.

[0027] Compared with the prior art, the present invention has the following advantages:

[0028] 1. The mixed metal abrasive particle differentiation device based on variable frequency detection technology provided by the present invention adopts variable frequency detection technology to distinguish metal particles of different materials. Compared with traditional magnetic field detection or conductivity detection, it has higher detection sensitivity and accuracy.

[0029] 2. The aliased metal abrasive particle differentiation device based on variable frequency detection technology provided by the present invention can solve the problem of low-precision detection of the inductive detection method in the existing oil state monitoring technology. It can realize real-time and online detection of metal particles in the hydraulic system and lubrication system of various mechanical equipment while having high detection accuracy and infinite detection flux. It can be applied to the wear state detection of actual large-scale equipment, and has important social significance and very considerable application prospects in the field of mechanical equipment fault diagnosis.

[0030] Based on the above reasons, the present invention can be widely promoted in fields such as wear particle detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0032] Figure 1 This is a schematic diagram of the structure of the inductive detection chip of the present invention.

[0033] Figure 2 This is a schematic diagram of the detection coil structure of the present invention.

[0034] Figure 3 This is a schematic diagram of the frequency conversion excitation circuit and data acquisition circuit of the present invention.

[0035] Figure 4 This is a graph showing the detection results of a single 70μm iron particle provided by an embodiment of the present invention.

[0036] Figure 5 This is a graph showing the detection results of a single 200μm copper particle provided by an embodiment of the present invention.

[0037] Figure 6 This is a graph showing the detection results of aliasing of 70μm iron particles and 200μm copper particles provided by an embodiment of the present invention.

[0038] In the figure: 1. Coil; 2. Metal particles; 3. Signal source; 4. Regulator; 5. Feedback circuit; 6. Inductive detection chip; 7. Amplifier; 8. Filter; 9. A / D converter; 10. Processor; 11. Microchannel; 12. Metal particle inlet; 13. Metal particle outlet; 14. Glass substrate. DETAILED DESCRIPTION

[0039] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0040] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0041] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0042] Unless otherwise specifically stated, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​described in these embodiments do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The techniques, methods and equipment known to ordinary technicians in the relevant fields may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific value should be interpreted as merely exemplary and not as a limitation. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, so once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0043] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention: the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0044] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below their position devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0045] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0046] The present invention provides a device for distinguishing aliased metal abrasive particles based on variable frequency detection technology, comprising: a sensor detection circuit, a variable frequency excitation circuit, and a data acquisition circuit; wherein:

[0047] The variable frequency excitation circuit is used to provide excitation signals of different frequencies to the sensor detection circuit, so that the magnetic field strength of the coil continuously changes, thereby generating magnetic fields of different strengths;

[0048] The sensor detection circuit generates an alternating magnetic field through the excitation signal applied by the variable frequency excitation circuit, and generates magnetic field changes of different intensities according to changes in the excitation signal, thereby magnetizing the metal particles through the magnetic field;

[0049] The data acquisition circuit is used to collect the inductance signal caused by the passing of metal particles and process the inductance signal.

[0050] When specifically implemented, as a preferred embodiment of the present invention, Figure 3 As shown, the variable frequency excitation circuit includes a signal source 3, a regulator 4, and a feedback circuit 5; wherein:

[0051] The signal source 3 generates a stable voltage or current signal for stimulating the sensor detection circuit;

[0052] The regulator 4 is used to adjust the gain, bias or conversion of the signal as needed to adapt to different application scenarios;

[0053] The feedback circuit 5 makes the signal output by the amplifier 7 stable, accurate and automatically calibrated through feedback control.

[0054] When specifically implemented, as a preferred embodiment of the present invention, Figure 1-2 As shown, the sensor detection circuit includes an inductive detection chip 6 and metal particles 2, wherein:

[0055] The inductive detection chip 6 includes a glass substrate 14 and a sensor module disposed on the glass substrate 14; the sensor module includes a microchannel 11, a metal particle inlet 12 and a metal particle outlet 13 respectively provided at both ends of the microchannel 11, and a coil 1 wound around the microchannel 11, with both ends of the coil 1 respectively connected to the variable frequency excitation circuit; in this embodiment, the coil 1 is preferably wound with a wire, and when an AC voltage is applied to the coil 1, an alternating magnetic field is induced to magnetize the metal particles 2 entering therein;

[0056] The metal particles 2 are metal abrasive particles generated by bearing wear and gearbox wear in various mining machines, ships, and offshore wind power machinery and equipment. The metal abrasive particles are distributed throughout the lubricating oil and hydraulic oil of the entire mechanical system and flow with the oil. The size and material of the metal abrasive particles are important criteria for judging equipment wear.

[0057] When specifically implemented, as a preferred embodiment of the present invention, Figure 3 As shown, the data acquisition circuit includes an amplifier 7, a filter 8, an A / D converter 9 and a processor 10, wherein:

[0058] The amplifier 7 is connected to the inductive detection chip 6 and is used to amplify the weak signal output by the inductive detection chip 6 to a measurable or processable range;

[0059] The filter 8 filters out noise and interference in the output signal of the inductive detection chip 6 to improve signal quality;

[0060] The A / D converter 9 is used to convert analog signals into digital signals for digital processing and storage;

[0061] The processor 10 is used to process, calculate and control digital signals, such as filtering, sampling, averaging, integration, micro-processing, etc.

[0062] An embodiment of the present invention further provides a method for distinguishing aliased metal abrasive particles based on the above-mentioned aliased metal abrasive particle distinguishing device and frequency conversion detection technology, comprising:

[0063] The variable frequency excitation circuit is used to perform multiple excitations on the coil in the sensor detection circuit, thereby changing the eddy current effect intensity of the metal particles. The data acquisition circuit collects the output signal of the sensor module in the sensor detection circuit to achieve the distinction between single iron particles, single copper particles, and aggregated metal particles of different materials, that is:

[0064] First, place the grinding fluid to be tested into the detection device. The metal abrasive particles in the grinding fluid will be detected by the sensor and emit a corresponding signal. The sensor uses a variable frequency excitation method to explore the response relationship between the inductive effect and eddy current effect of tiny abrasive particles and the excitation frequency to distinguish metal particles of different materials. Specifically:

[0065] The inductance signal of iron particles does not change significantly with the excitation frequency, and the smaller the particles, the smaller the effect of the excitation frequency on the output signal; the inductance signal output by copper particles is greatly affected by the excitation frequency. When the excitation frequency is low-frequency excitation, the inductance change generated by the copper particles passing through the sensor module is less than the lower detection limit of the instrument. When the excitation frequency is high-frequency excitation, the signal changes significantly. When the excitation frequency is 0.1MHz, the inductance change generated by the copper particles passing through the sensor is weak; when the excitation frequency is 2MHz, the signal changes significantly. Therefore, the eddy current effect intensity of the copper particles can be changed by frequency conversion to achieve the distinction between single iron particles, single copper particles, and aggregated metal particles of different materials. Figure 4 As shown in the figure, it is the detection result of a single 70μm iron particle. Figure 5 As shown in the figure, it is the detection result of a single 200μm copper particle. Figure 6 As shown in FIG, it is the detection result diagram of the aliasing of 70μm iron particles and 200μm copper particles.

[0066] In summary, the present invention uses variable frequency detection technology to distinguish metal particles of different materials, achieving higher sensitivity and accuracy than traditional magnetic field or conductivity detection. Furthermore, the present invention provides a novel method to mitigate the impact of simultaneous passage of particles of different materials on sensor accuracy, effectively resolving the detection issue when mixed particles are present.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A device for distinguishing aliased metal abrasive particles based on variable frequency detection technology, characterized in that: include: Sensor detection circuit, frequency conversion excitation circuit and data acquisition circuit; wherein: The variable frequency excitation circuit is used to provide excitation signals of different frequencies to the sensor detection circuit, so that the magnetic field strength of the coil continuously changes, thereby generating magnetic fields of different strengths; The sensor detection circuit generates an alternating magnetic field through the excitation signal applied by the variable frequency excitation circuit, and generates magnetic field changes of different intensities according to changes in the excitation signal, thereby magnetizing the metal particles through the magnetic field; The data acquisition circuit is used to collect the inductance signal caused by the passing of metal particles and process the inductance signal; The aliased metal abrasive particle distinguishing device combines the relationship between the inductance signal caused by the metal abrasive particles and the excitation frequency to distinguish between single iron particles, single copper particles, and aggregated metal particles of different materials, specifically including: The inductance signal generated by the iron particles does not change significantly with the excitation frequency, and the smaller the particles, the smaller the effect of the excitation frequency on the output signal; The inductance signal generated by copper particles is greatly affected by the excitation frequency. When the excitation frequency is low-frequency excitation, the inductance change generated by the copper particles is less than the instrument detection limit. When the excitation frequency is high-frequency excitation, the inductance signal changes significantly.

2. The aliased metal abrasive particle distinguishing device based on frequency conversion detection technology according to claim 1 is characterized in that: The variable frequency excitation circuit includes a signal source, a regulator, and a feedback circuit; wherein: The signal source generates a stable voltage or current signal for stimulating the sensor detection circuit; The regulator is used to adjust the gain, bias or conversion of the signal as needed to adapt to different application scenarios; The feedback circuit makes the signal output by the amplifier stable, accurate and automatically calibrated through feedback control.

3. The aliased metal abrasive particle distinguishing device based on frequency conversion detection technology according to claim 1 is characterized in that: The sensor detection circuit includes an inductive detection chip and metal particles, wherein: The inductive detection chip includes a glass substrate and a sensor module disposed on the glass substrate; the sensor module includes a microchannel, a metal particle inlet and a metal particle outlet respectively provided at both ends of the microchannel, and a coil wound around the microchannel, wherein both ends of the coil are respectively connected to the variable frequency excitation circuit; The metal particles are metal abrasive particles generated by bearing wear and gearbox wear in different mining machines, ships and offshore wind power machinery and equipment. The metal abrasive particles are distributed throughout the lubricating oil and hydraulic oil of the entire mechanical system and flow with the oil. The size and material of the metal abrasive particles are important bases for judging equipment wear.

4. The aliased metal abrasive particle distinguishing device based on frequency conversion detection technology according to claim 3 is characterized in that: The data acquisition circuit includes an amplifier, a filter, an A / D converter and a processor, wherein: The amplifier is connected to the inductive detection chip and is used to amplify the weak signal output by the inductive detection chip to a measurable or processable range; The filter removes noise and interference from the output signal of the inductive detection chip to improve signal quality; The A / D converter is used to convert analog signals into digital signals for digital processing and storage; The processor pair is used to process, calculate and control digital signals.

5. A method for distinguishing aliased metal abrasive particles based on a variable frequency detection technology and the aliased metal abrasive particle distinguishing device according to any one of claims 1 to 4, characterized in that: include: The variable frequency excitation circuit is used to perform multiple excitations on the coil in the sensor detection circuit, thereby changing the eddy current effect intensity of the metal particles. The data acquisition circuit collects the inductance signal output by the sensor module in the sensor detection circuit to achieve the distinction between single iron particles, single copper particles, and aggregated metal particles of different materials. The method for distinguishing aliased metal abrasive particles combines the relationship between the inductance signal caused by metal abrasive particles and the excitation frequency to distinguish between single iron particles, single copper particles, and aggregated metal particles of different materials. Specifically, it includes: The inductance signal generated by the iron particles does not change significantly with the excitation frequency, and the smaller the particles, the smaller the effect of the excitation frequency on the output signal; The inductance signal generated by copper particles is greatly affected by the excitation frequency. When the excitation frequency is low-frequency excitation, the inductance change generated by the copper particles is less than the instrument detection limit. When the excitation frequency is high-frequency excitation, the inductance signal changes significantly.

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