An oil-liquid agglomerated wear particle detection system based on digital phase lock

Abstract

The present invention provides an oil agglomerated wear particle detection system based on digital phase lock, which realizes the detection of agglomerated wear particles through the amplitude and phase relationship between metal material and output signal. The system comprises: an agglomerated wear particle detection sensor and a digital phase lock circuit with self-excitation, wherein the agglomerated wear particle detection sensor comprises a sensing unit and a flow channel unit; the sensing unit comprises a first excitation coil, an induction coil, and a second excitation coil; the flow channel unit comprises a flow channel and an oil inlet and an oil inlet at both ends of the flow channel; the first excitation coil, the induction coil, and the second excitation coil are sequentially sleeved on the flow channel; the digital phase lock circuit integrates an excitation module, a phase lock amplification module and a host computer communication module; the excitation module provides an excitation signal to the excitation coil; the phase lock amplification module processes the induced voltage signal caused by the passing of the wear particles and outputs it as an X value and a Y value according to sine and cosine components; and the host computer communication module transmits the processed signal to a computer display port.

Description

Technical Field

[0001] The present invention relates to the technical field of wear particle detection, and in particular to an oil agglomerated wear particle detection system based on digital phase locking. Background Art

[0002] When large-scale machinery is in operation, micron-sized abrasive particles generated by internal structural wear will flow with the lubricating oil. Therefore, the condition of the abrasive particles in the lubricating oil can most directly reflect the wear status of the equipment. Especially for large-scale equipment used in special operations, the operating environment of its key friction pairs is the most harsh, and it is also the weak link most prone to failure. Once problems such as poor lubrication, improper matching, and excessive temperature occur, abnormal wear is very likely to occur, leading to major failures.

[0003] Current oil detection technology primarily involves sampling and sending samples to a laboratory for testing. While this allows for comprehensive analysis, it requires extensive instrumentation and analysis, resulting in lengthy analysis cycles and the inability to perform online testing. Furthermore, the fluidity of oil makes agglomerated wear particles a common occurrence in practical oil systems. This is particularly true when two types of agglomerates with different magnetic field effects aggregate, causing interference between their signals, severely impacting detection accuracy. Limited by the single-signal detection capability, most oil wear sensors are unable to accurately detect agglomerated wear particles, resulting in low confidence in the test results. Consequently, there is an urgent need for high-precision, highly reliable oil detection sensors. Summary of the Invention

[0004] In response to the technical problems raised above, a system for detecting oil-agglomerated abrasive particles based on digital phase locking is provided. The present invention realizes the detection of agglomerated abrasive particles through the amplitude and phase relationship between the metal material and the output signal, thereby laying the foundation for the accurate detection of wear abrasive particles.

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

[0006] An oil agglomerated wear particle detection system based on digital phase lock includes: an agglomerated wear particle detection sensor and a digital phase lock circuit with self-excitation, wherein:

[0007] An agglomerated wear particle detection sensor includes a sensor base, a sensing unit and a flow channel unit arranged on the sensor base; wherein:

[0008] The sensing unit includes a first excitation coil, an induction coil, a second excitation coil and a PCB board for coil connection;

[0009] The flow channel unit includes a flow channel, an oil outlet and an oil inlet at both ends of the flow channel; the connection relationship is as follows:

[0010] The first excitation coil, the induction coil and the second excitation coil are sequentially sleeved on the flow channel, and the coil connections are welded on the sensor base using a PCB board;

[0011] The digital phase-locked circuit integrates an excitation module, a phase-locked amplifier module, and a host computer communication module; wherein:

[0012] an excitation module, connected to the first excitation coil and the second excitation coil, and configured to provide an excitation signal to the first excitation coil and the second excitation coil;

[0013] The phase-locked amplifier module is connected to the induction coil and is used to process the induced voltage signal caused by the passing of the abrasive particles and output it as X and Y values ​​according to the sine and cosine components;

[0014] The host computer communication module is connected to the phase-locked amplifier module and is used to transmit the processed signal to the computer display port. At the same time, the circuit parameters can be set through the computer display port.

[0015] Furthermore, by comparing and analyzing the X value and the Y value, the content of ferromagnetic particles and non-ferromagnetic particles in the agglomerated particles is obtained, specifically including:

[0016] When the particle size of the iron abrasive increases, the peak-to-peak value of the signal increases, while the output phase does not change, and the X-value phase and Y-value phase of the iron abrasive are opposite;

[0017] When the copper abrasive particle size increases, the peak-to-peak value of the signal increases, while the output X-value phase and Y-value phase are the same;

[0018] When copper abrasive particles agglomerate with iron abrasive particles, the output X and Y values ​​are both positive, but the X value is significantly greater than that of a single abrasive particle, and the Y value is smaller than that of a single abrasive particle;

[0019] When copper abrasive particles agglomerate with iron abrasive particles, the output X-value phase does not change, but the peak-to-peak value increases, and the Y-value phase changes, which is the same as the phase of the abrasive particles that have a strong influence on the magnetic field.

[0020] Furthermore, the runner is manufactured by a lost wax method, and the specific manufacturing process includes:

[0021] A wax flow channel model is made of wax, and insulating resin is poured into the cavity of the agglomerated wear particle detection sensor. After the resin is solidified, the wax flow channel model is melted by heating to form a flow channel.

[0022] Furthermore, the excitation module provides synchronous excitation signals to the first excitation coil and the second excitation coil, so that the first excitation coil and the second excitation coil generate magnetic fields of the same magnitude and opposite directions.

[0023] Furthermore, both ends of the induction coil are connected to signal output lines, which are connected using aviation plugs to further improve the shielding effect of the agglomerated wear particle detection sensor.

[0024] Furthermore, an oil outlet fixing plate and an oil inlet fixing plate are provided in the flow channel unit, for fixing the oil outlet and the oil inlet respectively.

[0025] Furthermore, the agglomerated wear particle detection sensor further includes a sensor cover, and the sensor base and the sensor cover are packaged with shielding materials to reduce external electromagnetic interference.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] 1. The present invention provides an oil agglomerated abrasive particle detection system based on digital phase-locking. In order to solve the problem of difficulty in detecting agglomerated abrasive particles, a three-coil sensor is designed, and a digital phase-locking board is used to obtain a multi-parameter abrasive particle detection signal. Analysis shows that when iron abrasive particles pass through the sensor, the real and imaginary parts of the induced voltage output by the sensor are in opposite phases, while the real and imaginary parts of the induced voltage output by copper abrasive particles are the same. Therefore, when the abrasive particles agglomerate, the real parts of the signals cancel each other out, and the imaginary parts are superimposed on each other. The X and Y values ​​of the sensor output signal were obtained through experiments. Finally, the agglomerated abrasive particle experiment was carried out based on the relationship between the X and Y values, and the relationship between the agglomerated abrasive particle size and the signal change was obtained, confirming the feasibility of the method. This work can be used to improve the detection accuracy of oil detection sensors and provide more reliable data information for subsequent equipment status judgment.

[0028] 2. The present invention provides an oil-liquid agglomerated wear particle detection system based on digital phase locking, which does not require changing the excitation frequency and adopts a modular design as a whole. It does not require complex instruments, and the entire device has higher detection accuracy, solving the problems of difficult agglomerated particle detection and low output signal credibility.

[0029] Based on the above reasons, the present invention can be widely promoted in fields such as wear particle detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] 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.

[0031] Figure 1 Schematic diagram of the internal structure of the agglomerated wear particle detection sensor of the present invention.

[0032] Figure 2This is a schematic diagram of the structure of the agglomerated wear particle detection sensor of the present invention.

[0033] Figure 3 This is a structural block diagram of a digital phase-locked circuit with self-excitation according to the present invention.

[0034] Figure 4 This is a diagram of the detection results of a single iron abrasive particle provided in an embodiment of the present invention.

[0035] Figure 5 This is a graph showing the test results of a single copper abrasive particle provided in an embodiment of the present invention.

[0036] Figure 6 This is a curve of the detection results of iron abrasive particles provided by an embodiment of the present invention.

[0037] Figure 7 This is a curve of the detection results of copper abrasive particles provided by an embodiment of the present invention.

[0038] Figure 8 This is a diagram showing the detection results of the agglomeration of iron abrasive particles and copper abrasive particles provided in an embodiment of the present invention.

[0039] In the figure: 1. First excitation coil; 2. Induction coil; 3. Second excitation coil; 4. Oil outlet; 5. Oil inlet; 6. PCB board for coil connection; 7. Oil outlet fixing plate; 8. Sensor base; 9. Oil inlet fixing plate; 10. Sensor cover; 11. Signal output line; 12. Flow channel. DETAILED DESCRIPTION

[0040] In order to enable those skilled in the art to better understand the solutions of the present invention, 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 embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts should fall within the scope of protection of the present invention.

[0041] It should be noted that the terms "first", "second", etc. in the description and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that the numbers used in this way can be interchanged where appropriate, so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device that includes a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices.

[0042] The present invention provides an oil agglomerated wear particle detection system based on digital phase lock, comprising: an agglomerated wear particle detection sensor and a digital phase lock circuit with self-excitation, wherein:

[0043] like Figure 1 、 2 As shown, the agglomerated wear particle detection sensor includes a sensor base 8, a sensing unit and a flow channel unit arranged on the sensor base 8; wherein:

[0044] The sensing unit includes a first excitation coil 1, an induction coil 2, a second excitation coil 3 and a PCB board 6 for connecting the coils;

[0045] The flow channel unit includes a flow channel 12, an oil outlet 4 and an oil inlet 5 provided at both ends of the flow channel 12; the connection relationship is as follows:

[0046] The first excitation coil 1, the induction coil 2 and the second excitation coil 3 are sequentially sleeved on the flow channel 12, and the coil connection PCB board 6 is welded on the sensor base 8;

[0047] like Figure 3 As shown, the digital phase-locked circuit integrates an excitation module, a phase-locked amplifier module and a host computer communication module; wherein:

[0048] An excitation module, connected to the first excitation coil 1 and the second excitation coil 3, for providing an excitation signal to the first excitation coil 1 and the second excitation coil 3;

[0049] The phase-locked amplifier module is connected to the induction coil 2 and is used to process the induced voltage signal caused by the passing of the abrasive particles and output it as X and Y values ​​according to the sine and cosine components;

[0050] The host computer communication module is connected to the phase-locked amplifier module and is used to transmit the processed signal to the computer display port. At the same time, the circuit parameters can be set through the computer display port.

[0051] In this embodiment, a digital phase-locked board is used to provide an excitation signal and a reference signal. The reference signal is generated inside the board, and the signal has very low distortion, which can ensure the reliability of the reference signal. The voltage value of the excitation signal generated by the board is low, so the signal energy is amplified by a power amplifier, thereby enhancing the magnetic field generated by the first excitation coil 1 and the second excitation coil 3. The induced voltage output by the induction coil 2 is connected to the signal input terminal of the board, and then the signal-to-noise ratio of the signal is further improved through phase-locked amplification and low-pass filtering. The processed signal is transmitted to the computer port via 485 communication. At the same time, the computer port can adjust the excitation frequency, amplification factor and filtering parameters of the board, and then adapt to different sensors.

[0052] In specific implementation, as a preferred embodiment of the present invention, the content of ferromagnetic particles and non-ferromagnetic particles in the agglomerated particles is obtained by comparative analysis of the X value and the Y value, specifically including:

[0053] When the particle size of the iron abrasive increases, the peak-to-peak value of the signal increases, while the output phase does not change, and the X-value phase and Y-value phase of the iron abrasive are opposite;

[0054] When the copper abrasive particle size increases, the peak-to-peak value of the signal increases, while the output X-value phase and Y-value phase are the same;

[0055] When copper abrasive particles agglomerate with iron abrasive particles, the output X and Y values ​​are both positive, but the X value is significantly greater than that of a single abrasive particle, and the Y value is smaller than that of a single abrasive particle;

[0056] When copper abrasive particles agglomerate with iron abrasive particles, the output X-value phase does not change, but the peak-to-peak value increases, and the Y-value phase changes, which is the same as the phase of the abrasive particles that have a strong influence on the magnetic field.

[0057] In specific implementation, as a preferred embodiment of the present invention, the flow channel 12 is manufactured by a lost wax method, and the specific manufacturing process includes:

[0058] A wax flow channel model is made of wax, and insulating resin is poured into the cavity of the agglomerated wear particle detection sensor. After the resin is solidified, the wax flow channel model is melted by heating to form a flow channel 12.

[0059] In specific implementation, as a preferred embodiment of the present invention, the excitation module provides synchronous excitation signals to the first excitation coil 1 and the second excitation coil 3, so that the first excitation coil 1 and the second excitation coil 3 generate magnetic fields of the same magnitude and opposite directions.

[0060] In specific implementation, as a preferred embodiment of the present invention, both ends of the induction coil 2 are connected to the signal output line 11, and the signal output line 11 is connected using an aviation plug to further improve the shielding effect of the agglomerated wear particle detection sensor.

[0061] When implementing the invention, please refer to the preferred embodiment of the invention. Figure 1 In the flow channel unit, an oil outlet fixing plate 7 and an oil inlet fixing plate 9 are also provided, which are used to fix the oil outlet 4 and the oil inlet 5 respectively.

[0062] When specifically implemented, as a preferred embodiment of the present invention, see Figure 2 The agglomerated wear particle detection sensor further includes a sensor cover 10 . The sensor base 8 and the sensor cover 10 are packaged with shielding materials to reduce external electromagnetic interference.

[0063] Example

[0064] First, iron abrasive particles, copper abrasive particles, and a mixture of copper and iron abrasive particles of different sizes are stuck to a nylon wire through a microscope. Then the nylon wire with abrasive particles is passed through the sensor. The abrasive particles are controlled to move back and forth in the sensor detection area by moving the slide. The signal output by the digital phase-locked amplifier board is read using data reading software. The excitation frequency selected for the abrasive particle detection experiment is 90KHz.

[0065] The detection of agglomerated abrasive particles first depends on differentiation, that is, distinguishing whether the measured abrasive particles are single abrasive particles or agglomerated abrasive particles of different materials. Therefore, it is necessary to first test the sensor's ability to detect single abrasive particles, so as to obtain the sensor's detection accuracy and the voltage change law of a single abrasive particle. Because the output signal of the three-coil sensor is related to the direction in which the abrasive particles pass, in order to ensure the accuracy of the output signal phase, it is necessary to select the signal with the same direction in which the abrasive particles pass. Figure 4 and 5 As shown in the figure, when a single iron abrasive particle and a single copper abrasive particle pass through the sensor, the X value and Y value output, when the iron abrasive particle size increases, the peak-to-peak value of the signal increases, while the output phase does not change, and the X value phase and Y value phase of the iron abrasive particle are opposite. When the copper abrasive particle size increases, the peak-to-peak value of the signal increases, while the output X value phase and Y value phase are the same. Figure 8 As shown in the figure, when copper abrasive particles agglomerate with iron abrasive particles, the output X and Y values ​​are both positive, but the X value is significantly greater than that of a single abrasive particle, and the Y value is smaller than that of a single abrasive particle. When copper abrasive particles agglomerate with iron abrasive particles, the output X value phase does not change, but the peak-to-peak value increases, and the Y value phase changes. Its phase is the same as that of the abrasive particles with a strong influence on the magnetic field.

[0066] More specifically, by Figure 6 and Figure 7 It can be seen that when the sensor detects agglomerated particles, the X value of the output signal is added and the Y value is subtracted. Figure 8 As shown in the figure, when 340μm copper particles agglomerate with 78μm iron particles, the output X and Y values ​​are the same, but the X value is significantly greater than that of a single particle, while the Y value is smaller. However, when 340μm copper particles agglomerate with 178μm iron particles, the output X value phase remains unchanged, but the peak-to-peak value increases, and the Y value phase becomes opposite, becoming the same as that of the iron particles. This is because the change in Y value caused by the 178μm iron particles offsets the change caused by the 340μm copper particles, as magnetic iron particles have a stronger influence on the magnetic field than copper particles. By comparing the X and Y values, we can determine the content of ferromagnetic and non-ferromagnetic particles in the agglomerated particles.

[0067] In summary, the present invention addresses the problem of difficulty in inspecting agglomerated metal abrasive particles. By utilizing the different effects of ferromagnetic abrasive particles and non-ferromagnetic abrasive particles on the impedance characteristics of the detection coil, a three-coil sensor based on digital phase locking is designed. The amplitude and phase relationship of agglomerated abrasive particles in different signal output channels is obtained through digital phase locking technology. That is, ferromagnetic abrasive particles and non-ferromagnetic abrasive particles have different phase changes in the coil inductance and impedance signals. Therefore, the real and imaginary parts of the induced voltage output by ferromagnetic abrasive particles have opposite phases, while the real and imaginary parts of the induced voltage output by copper abrasive particles have the same phase. The phase difference between the real and imaginary parts is used to achieve differentiated detection of agglomerated abrasive particles. The present invention can achieve accurate detection of oil contaminants using a simple detection method, which has a good reference value for subsequent research on high-precision detection equipment.

[0068] 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. An oil agglomerated wear particle detection system based on digital phase lock, characterized in that: include: Agglomerated wear particle detection sensor and digital phase-locked circuit with self-excitation, wherein: An agglomerated wear particle detection sensor comprises a sensor base (8), a sensing unit and a flow channel unit arranged on the sensor base (8); wherein: The sensing unit comprises a first excitation coil (1), an induction coil (2), a second excitation coil (3), and a PCB board (6) for connecting the coils; The flow channel unit includes a flow channel (12), an oil outlet (4) and an oil inlet (5) provided at both ends of the flow channel (12); the connection relationship is as follows: The first excitation coil (1), the induction coil (2), and the second excitation coil (3) are sequentially sleeved on the flow channel (12), and the coil connection PCB board (6) is welded on the sensor base (8); The digital phase-locked circuit integrates an excitation module, a phase-locked amplifier module, and a host computer communication module; wherein: an excitation module connected to the first excitation coil (1) and the second excitation coil (3), and configured to provide an excitation signal to the first excitation coil (1) and the second excitation coil (3); The phase-locked amplifier module is connected to the induction coil (2) and is used to process the induced voltage signal caused by the passing of the abrasive particles and output it as an X value and a Y value according to the sine and cosine components; by comparing and analyzing the X value and the Y value, the content of the ferromagnetic particles and the non-ferromagnetic particles in the agglomerated particles is obtained, specifically including: When the particle size of the iron abrasive increases, the peak-to-peak value of the signal increases, while the output phase does not change, and the X-value phase and Y-value phase of the iron abrasive are opposite; When the copper abrasive particle size increases, the peak-to-peak value of the signal increases, while the output X-value phase and Y-value phase are the same; When copper abrasive particles agglomerate with iron abrasive particles, the output X and Y values ​​are both positive, but the X value is significantly greater than that of a single abrasive particle, and the Y value is smaller than that of a single abrasive particle; When copper abrasive particles agglomerate with iron abrasive particles, the output X-value phase does not change, but the peak-to-peak value increases, and the Y-value phase changes, and its phase is the same as that of the abrasive particles with a strong influence on the magnetic field; The host computer communication module is connected to the phase-locked amplifier module and is used to transmit the processed signal to the computer display port. At the same time, the circuit parameters can be set through the computer display port.

2. The oil agglomerated wear particle detection system based on digital phase lock according to claim 1 is characterized in that: The flow channel (12) is manufactured by the lost wax method, and the specific manufacturing process includes: A wax flow channel model is made by using wax, and insulating resin is poured into the cavity of the agglomerated wear particle detection sensor. After the resin is solidified, the wax flow channel model is melted by heating to form a flow channel (12).

3. The oil agglomerated wear particle detection system based on digital phase lock according to claim 1 is characterized in that: The excitation module provides synchronous excitation signals to the first excitation coil (1) and the second excitation coil (3), so that the first excitation coil (1) and the second excitation coil (3) generate magnetic fields of the same magnitude and opposite directions.

4. The oil agglomerated wear particle detection system based on digital phase lock according to claim 1 is characterized in that: Both ends of the induction coil (2) are connected to a signal output line (11), and the signal output line (11) is connected using an aviation plug, so as to further improve the shielding effect of the agglomerated wear particle detection sensor.

5. The oil agglomerated wear particle detection system based on digital phase lock according to claim 1 is characterized in that: An oil outlet fixing plate (7) and an oil inlet fixing plate (9) are also provided in the flow channel unit, and are used to fix the oil outlet (4) and the oil inlet (5), respectively.

6. The oil agglomerated wear particle detection system based on digital phase lock according to claim 1 is characterized in that: The agglomerated wear particle detection sensor further comprises a sensor upper cover (10), and the sensor base (8) and the sensor upper cover (10) are packaged with shielding material to reduce external electromagnetic interference.

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