An inductance-integrated metal dust sensor and method for identifying a dust component

Abstract

The application discloses an inductance integrated metal dust sensor and method for identifying dust components, and the sensor comprises a main passage and a measuring bypass, the measuring bypass is arranged in a U shape on one side of the main passage, an electromagnetic induction element is arranged on the inlet side and the outlet side of the measuring bypass respectively, and a lens-free optical blocking method detection device is arranged between the two electromagnetic induction elements; after ferromagnetic metal dust enters the measuring bypass from the main passage, the ferromagnetic metal dust sequentially passes through the electromagnetic induction element on the inlet side, the lens-free optical blocking method detection device and the electromagnetic induction element on the outlet side; the diameter of the measuring bypass is smaller than the diameter of the main passage so as to reduce the flow.

Description

Technical Field

[0001] This invention belongs to the field of aero-engine health monitoring technology, and in particular, it is a narrow-space wide-area image and inductively integrated metal debris sensor and method for aero-engines that can identify debris components. Background Technology

[0002] Online detection of metal shavings is crucial for the health monitoring of aero-engines. Large metal shavings generated by sudden abnormal wear such as spindle fatigue wear do not significantly alter the concentration of metal shavings in the lubricating oil, nor do they continuously produce abnormal metal shavings. These are difficult to detect offline, yet they are precursors to major malfunctions and must be monitored using online metal shavings detection methods. Besides the size of the metal shavings, their composition contains important wear information, helping to determine their source, assess the fault condition, and facilitate faster fault location by maintenance personnel, thus reducing maintenance costs. Therefore, obtaining both the size and composition of metal shavings from aero-engines is essential.

[0003] However, existing online detection methods for metal debris in aero-engines can only obtain the size and shape of the metal debris. For example, optically based metal debris sensors obtain the quantity, size, and shape of the metal debris by acquiring images, while electrically based metal debris sensors obtain the size and quantity of the metal debris through inductance, capacitance, and resistance detection methods. Although online X-ray fluorescence spectroscopy can detect the composition of metal debris online, the limited sensor installation space in aero-engine lubrication systems restricts its application. Furthermore, the high-temperature, vibration, and wide-flow-range application scenarios of aero-engines place special requirements on metal debris sensors. Therefore, there is an urgent need for a confined space, wide-flow-range imaging, and inductively integrated metal debris sensor for aero-engines that can identify debris composition. This sensor should be able to be installed in the confined space of the aero-engine lubrication system, have a high inner diameter to operate in a wide flow range, and simultaneously monitor metal debris, obtaining the quantity, size, shape, and composition of some metal debris, providing more comprehensive information for aero-engine health monitoring. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an inductively integrated metal debris sensor for identifying debris composition. By using bypass detection to reduce the flow through the sensor, both image and inductive detection methods can be used for metal debris detection, enabling the detection of small-sized metal debris. The sensor uses a lensless photoresist method for online detection of metal debris, obtaining its size and shape. It also uses inductive principles to detect ferromagnetic metal debris, obtaining size information related to the ferromagnetism of the debris. Based on the principle that both the size and ferromagnetism of the metal debris affect the electromagnetic induction signal, the actual shape and size of the metal debris obtained by the lensless photoresist method, combined with the electromagnetic induction signal, determine the ferromagnetism of the metal debris material. Furthermore, the ferromagnetism of the materials used in aero-engines is used to determine the material of the metal debris. Through a combined image and inductive detection method, the size, shape, and material of the metal debris can be determined simultaneously, providing more comprehensive lubricating oil monitoring data for aero-engine fault prediction and health management.

[0005] The objective of this invention is achieved through the following technical solution:

[0006] An inductively integrated metal debris sensor for identifying debris composition includes a main path and a measurement bypass. The measurement bypass is U-shaped and located on one side of the main path. Electromagnetic induction elements are respectively arranged on the inlet and outlet sides of the measurement bypass, and a lensless photoresist detection device is arranged between the two electromagnetic induction elements. Ferromagnetic metal debris enters the measurement bypass from the main path and passes sequentially through the electromagnetic induction element on the inlet side, the lensless photoresist detection device, and the electromagnetic induction element on the outlet side. The diameter of the measurement bypass is smaller than the diameter of the main path to reduce the flow rate.

[0007] Furthermore, a wireless data interface is provided to transmit the detection results to the monitoring system in real time. The monitoring system is equipped with a computing unit to calculate the actual relative permeability of the corresponding ferromagnetic metal shavings.

[0008] The present invention also provides a method for identifying the components of debris, comprising:

[0009] A lensless optical obscuration detection device is used to obtain several frames of two-dimensional images of ferromagnetic metal shavings tumbling in lubricating oil. By processing and synthesizing these frames of two-dimensional images, a three-dimensional morphological image of the ferromagnetic metal shavings is obtained, and the actual equivalent radius r of the ferromagnetic metal shavings is measured. The equivalent radius r' of the ferromagnetic metal shavings is measured by electromagnetic induction elements on the inlet side and the outlet side. When the same ferromagnetic metal shavings are detected, the actual relative permeability u of the corresponding ferromagnetic metal shavings is calculated based on the actual equivalent radius r, the equivalent radius r', and the pre-calibrated relative permeability u0, and the material is determined accordingly.

[0010] Specifically, in the above methods:

[0011] The velocity v of the ferromagnetic metal shavings can be obtained from the time interval t between two two-dimensional images of the ferromagnetic metal shavings and the distance x traveled.

[0012]

[0013] From the distance x' between the inlet-side and outlet-side electromagnetic induction elements, and the actual interval t' detected between the inlet-side and outlet-side electromagnetic induction elements of the ferromagnetic metal debris, another velocity v' of the ferromagnetic metal debris is obtained:

[0014]

[0015] Since the velocity of the ferromagnetic metal shavings remains constant, when v and v' are the same, and the lensless photoresist detection device detects the ferromagnetic metal shavings approximately t' / 2 after the electromagnetic induction element on the inlet side detects them, then the electromagnetic induction element on the inlet side, the electromagnetic induction element on the outlet side, and the lensless photoresist detection device all detect the same ferromagnetic metal shavings. The relative permeability u of the ferromagnetic metal shavings can be calculated from the equivalent radius r' and actual equivalent radius r of the ferromagnetic metal shavings detected by the electromagnetic induction elements on the inlet and outlet sides.

[0016] u=f(r,r′) (3)

[0017] Electromagnetic induction elements were tested using ferromagnetic metal scraps of different shapes, sizes, and relative permeabilities. The relationship between the signal amplitude A and the actual equivalent radius r and the relative permeability u of the metal scraps was obtained.

[0018] A=f(r,u) (4)

[0019] For electromagnetic induction elements calibrated using materials with a relative permeability of u0, the following should be true:

[0020] f(r′,u0)=f(r,u) (5)

[0021] From (3) and (4), we can obtain

[0022] u=f(r,r′,u0) (6)

[0023] The relative permeability of the ferromagnetic metal shavings was obtained, and the corresponding relative permeability was obtained by testing the ferromagnetic material of the aero-engine.

[0024] {Material 1, Material 2, Material 3, ...} → {u1, u2, u3, ...} (7)

[0025] The material of the ferromagnetic metal shavings was then obtained.

[0026] f(r,r′,u0)→{Material i} (8)

[0027] In the formula, r is measured by a lensless photoresist detection device, r' is measured by an electromagnetic induction element on the inlet side and an electromagnetic induction element on the outlet side, and u0 is obtained when the electromagnetic induction element on the inlet side and an electromagnetic induction element on the outlet side are calibrated, thus realizing the material of ferromagnetic metal shavings by using image and inductance joint detection.

[0028] Compared with the prior art, the beneficial effects of the technical solution of the present invention are:

[0029] 1. By measuring the flow rate of the bypass shunt main path, the diameter of the detection channel can be reduced, thereby enabling both the electromagnetic induction element and the lensless photoresist device to effectively capture and measure metal shavings with diameters as low as tens of micrometers, significantly improving the online detection sensitivity for tiny wear particles.

[0030] 2. The lensless photoresist detection device provided by the present invention utilizes a photoresist array for direct imaging without a lens, can work stably in a wide flow range and is maintenance-free; based on multi-frame target tracking and three-dimensional reconstruction, it accurately obtains the actual equivalent radius r and shape information of the debris, making up for the deficiency of the single inductance method in evaluating the size of non-spherical or irregular debris.

[0031] 3. The equivalent radius r′ is obtained by synchronous measurement of electromagnetic induction elements on the inlet and outlet sides. Combined with the actual equivalent radius r, the actual relative permeability u is accurately calculated by using the pre-calibrated relative permeability u0. This allows us to infer the material type of the metal shavings (iron, cobalt, nickel-based alloys, etc.) and provide chemical composition clues for fault source location.

[0032] 4. This invention can fuse images and inductive signals in real time to achieve multi-dimensional information integration: joint detection can simultaneously collect data in four dimensions—quantity, size, shape, and material—in the same sensing path, constructing a more comprehensive profile of engine wear, improving the accuracy and lead time of fault prediction, and significantly reducing operation and maintenance costs.

[0033] 5. This invention achieves high integration and strong adaptability to a wide flow range in a confined space: It highly integrates optical and inductive dual-mode sensors into one unit, saving installation space; the lens-free photoresist method has strong anti-pollution ability, and combined with high temperature resistance and vibration resistance design, it meets the harsh environmental requirements of the fuel circuit of aero-engines. Attached Figure Description

[0034] Figure 1 A schematic diagram of the structure of the sensor of the present invention is shown.

[0035] Reference numerals: 1-Main path; 2-Measurement bypass; 3-Inlet side electromagnetic induction element; 4-Outlet side electromagnetic induction element; 5-Lensless photoresist detection device. Detailed Implementation

[0036] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only for explaining the present invention and are not intended to limit the present invention.

[0037] This embodiment provides an inductively integrated metal chip sensor for identifying chip composition. The sensor consists of a main sensor path 1, a measurement bypass path 2, an inlet-side electromagnetic induction element 3, an outlet-side electromagnetic induction element 4, and a lensless photoresist detection device 5. Figure 1 As shown. The main passage 1 is used to guide the lubricating oil containing metal shavings into the flow. The measuring bypass 2 has a smaller channel diameter than the main passage 1 to reduce the flow rate, which can reduce the flow rate to 10% to 50% of that of the main passage.

[0038] The sensor is also equipped with a wireless data interface for transmitting the detection results to the monitoring system in real time. The monitoring system has a computing unit for calculating the actual relative permeability of the corresponding ferromagnetic metal shavings.

[0039] After entering the measurement bypass 2 from the main passage 1, the ferromagnetic metal shavings first pass through the inlet-side electromagnetic induction element 3, then through the lensless photoresist detection device 5, and finally through the outlet-side electromagnetic induction element 4. During this process, the lensless photoresist detection device 5 acquires images of the ferromagnetic metal shavings. Through object tracking, it obtains multiple two-dimensional images of the ferromagnetic metal shavings tumbling in the lubricating oil. These multiple two-dimensional images are then processed and synthesized into a three-dimensional image to obtain the three-dimensional morphology of the ferromagnetic metal shavings, thus determining the actual equivalent radius r of the ferromagnetic metal shavings. The velocity v of the ferromagnetic metal shavings can be obtained from the time interval t between two images and the distance x traveled.

[0040]

[0041] From the distance x' between the inlet-side electromagnetic induction element 3 and the outlet-side electromagnetic induction element 4, and the actual distance t' detected between the inlet-side electromagnetic induction element 3 and the outlet-side electromagnetic induction element 4, another velocity v' of the ferromagnetic metal shavings can be obtained:

[0042]

[0043] Since the velocity of the ferromagnetic metal shavings remains constant, when v and v' are the same, and the lensless photoresist detection device 5 detects the ferromagnetic metal shavings approximately t' / 2 after the electromagnetic induction element 3 on the inlet side detects them, then the electromagnetic induction element 3 on the inlet side, the electromagnetic induction element 4 on the outlet side, and the lensless photoresist detection device 5 may all detect the same ferromagnetic metal shavings. If the ferromagnetic metal is large enough, and only this metal shaving meets the above conditions within a certain time interval, then it can be considered that the same ferromagnetic metal shaving has indeed been detected. The relative permeability u of the ferromagnetic metal shavings can be calculated from the equivalent radius r' and the actual equivalent radius r of the ferromagnetic metal shavings detected by the electromagnetic induction element 3 on the inlet side and the electromagnetic induction element 4 on the outlet side.

[0044] u=f(r,r′) (3)

[0045] Electromagnetic induction elements were tested using ferromagnetic metal scraps of different shapes, sizes, and relative permeabilities. The relationship between the signal amplitude A and the actual equivalent radius r and the relative permeability u of the metal scraps was obtained.

[0046] A=f(r,u) (4)

[0047] For electromagnetic induction elements calibrated using materials with a relative permeability of u0, the following should be true:

[0048] f(r′,u0)=f(r,u) (5)

[0049] From (3) and (4), we can obtain

[0050] u=f(r,r′,u0) (6)

[0051] The relative permeability of the ferromagnetic metal shavings can then be obtained. By testing the ferromagnetic materials of aero-engines, the corresponding relative permeability can be obtained, i.e.:

[0052] {Material 1, Material 2, Material 3, ...} → {u1, u2, u3, ...} (7)

[0053] The material of the ferromagnetic metal shavings was then obtained.

[0054] f(r,r′,u0)→{Material i} (8)

[0055] In the formula, r is measured by the lensless photoresist detection device 5, r' is measured by the inlet-side electromagnetic induction element 3 and the outlet-side electromagnetic induction element 4, and u0 is obtained during the calibration of the inlet-side electromagnetic induction element 3 and the outlet-side electromagnetic induction element 4, thereby realizing the material of ferromagnetic metal shavings by using image and inductance combined detection.

[0056] This invention is not limited to the embodiments described above. The above description of specific embodiments is intended to illustrate and explain the technical solutions of this invention. The specific embodiments described above are merely illustrative and not restrictive. Without departing from the spirit and scope of the claims, those skilled in the art can make many specific modifications based on the teachings of this invention, and these modifications all fall within the scope of protection of this invention.

Claims

1. A method for identifying the composition of dust particles, characterized in that, include: Several frames of two-dimensional images of ferromagnetic metal shavings tumbling in lubricating oil were obtained using a lensless optical obscuration method. These images were then processed and synthesized to obtain a three-dimensional morphology image of the ferromagnetic metal shavings, allowing for the measurement of the actual equivalent radius of the ferromagnetic metal shavings. r The equivalent radius of the ferromagnetic metal shavings was measured by the electromagnetic induction elements on the inlet and outlet sides. r’， When the same ferromagnetic metal shavings are detected, the actual equivalent radius r and the equivalent radius are compared. r’ The actual relative permeability u of the corresponding ferromagnetic metal shavings is calculated from the pre-calibrated relative permeability u0, and its material is determined accordingly. The time interval between two two-dimensional images of ferromagnetic metal shavings t Distance traveled x The velocity of the ferromagnetic metal shavings was obtained. v : （1）； The distance between the inlet-side electromagnetic induction element and the outlet-side electromagnetic induction element x’ The actual interval detected by the electromagnetic induction element on the inlet side and the electromagnetic induction element on the outlet side for ferromagnetic metal shavings. t’ The velocity of another ferromagnetic metal shaving is obtained. v’ : （2）； Since the velocity of ferromagnetic metal chips remains constant, when v and v’ Similarly, the lensless optical obscuration detection device detected ferromagnetic metal shavings precisely at the electromagnetic induction element on the inlet side. t’ / 2 After detecting ferromagnetic metal debris, the same ferromagnetic metal debris is detected by the inlet-side electromagnetic induction element, the outlet-side electromagnetic induction element, and the lensless photoresist detection device; the equivalent radius of the ferromagnetic metal debris detected by the inlet-side electromagnetic induction element and the outlet-side electromagnetic induction element. r’ equivalent radius r Find the relative permeability of the ferromagnetic metal shavings. u ,Right now （3）； Electromagnetic induction elements were tested using ferromagnetic metal shavings of different shapes, sizes, and relative permeabilities to obtain signal amplitudes. A equivalent radius r Relative permeability of metal shavings u Relationship: （4）； For using relative permeability u The electromagnetic induction element specified for material 0 should include: （5）； From (3) and (4), we can obtain （6） ； The relative permeability of the ferromagnetic metal shavings was obtained, and the corresponding relative permeability was obtained by testing the ferromagnetic material of the aero-engine. （7）； The material of the ferromagnetic metal shavings was then obtained. （8）； In the formula, r Measured by a lensless optical obscuration method detection device, r’ Measured by the electromagnetic induction element on the inlet side and the electromagnetic induction element on the outlet side. u 0 is obtained during the calibration of the electromagnetic induction element on the inlet side and the electromagnetic induction element on the outlet side, realizing the material of ferromagnetic metal shavings by combining image and inductance detection.

2. The method for identifying debris components according to claim 1, characterized in that, The ferromagnetic metal shavings sensor used in this method includes a main passage and a measurement bypass. The measurement bypass is U-shaped and located on one side of the main passage. Electromagnetic induction elements are respectively installed on the inlet and outlet sides of the measurement bypass, and a lensless photoresist detection device is installed between the two electromagnetic induction elements. After entering the measurement bypass from the main passage, the ferromagnetic metal shavings pass sequentially through the electromagnetic induction element on the inlet side, the lensless photoresist detection device, and the electromagnetic induction element on the outlet side. The diameter of the measurement bypass is smaller than the diameter of the main passage to reduce the flow rate.

3. The method for identifying debris components according to claim 2, characterized in that, It is also equipped with a wireless data interface for transmitting the detection results to the monitoring system in real time. The monitoring system is equipped with a computing unit to calculate the actual relative permeability of the corresponding ferromagnetic metal shavings.

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