A high-resolution wide-temperature-range metal abrasive particle detection sensitive element and sensor

Abstract

The application discloses a kind of high-resolution wide temperature range metal abrasive particle detection sensitive elements and sensor, belong to metal abrasive particle detection field, including two groups of symmetrical distribution coil group, each coil group is formed by excitation coil and detection coil, forms four coil differential bridge structure;Two groups of coil group are 180° reverse spiral winding on nanocrystalline soft magnetic core body, and coil wire diameter is distributed according to gradient, to realize bidirectional differential detection;The application adopts two groups of 180° reverse spiral coil to form wheatstone bridge, when abrasive particle passes, two groups of coils generate phase-opposed induced electromotive force, greatly improve the resolution of abrasive particle detection;The coil in the application adopts special three-layer insulation enameled wire, outer polyimide coating solves high temperature melting problem, middle layer nanometer ceramic insulation layer realizes high voltage resistance, inner polyurethane layer guarantees low temperature flexibility, significantly improve the reliability and service life of coil.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of metal abrasive particle detection, and particularly relates to a high-resolution wide-temperature-range metal abrasive particle detection sensitive element and sensor. BACKGROUND

[0002] In the running process of high-end equipment in the fields of energy, ship, aviation, etc., the wear condition of key components such as bearings, gears and transmission shafts directly affects the running safety and service life of the equipment. Timely and accurate detection of metal abrasive particles generated by the wear of these components is of great significance for the fault warning and maintenance of the equipment. However, the existing metal abrasive particle detection technology and sensors have many deficiencies, and it is difficult to meet the detection needs of high-end equipment under complex working conditions.

[0003] Traditional metal abrasive particle detection sensors have obvious limitations in temperature adaptation range. Most sensors use silicon steel sheets as core materials, and the magnetic permeability will decrease by more than 30% above 120℃, while the hysteresis loss will increase sharply below-20℃, and they cannot work stably in a wide temperature range of-40℃ to 200℃. For example, an existing patent technology can only work in a temperature range of-10℃ to 80℃, which limits its application in scenarios such as aviation engines and deep-sea ships that need to cope with extreme temperatures.

[0004] In terms of abrasive particle resolution capability, the detection signal strength of conventional double-coil structure sensors for non-ferromagnetic abrasive particles below 100μm, such as aluminum alloy abrasive particles, is usually less than 10μV, which is easily overwhelmed by environmental noise, resulting in inaccurate detection. In the existing technology, the resolution of non-ferromagnetic abrasive particles can only reach 200μm, which cannot meet the detection needs of high-end equipment for small abrasive particles.

[0005] In summary, there is a lack of a sensor that can achieve high-resolution metal abrasive particle detection in a wide temperature range and has good path adaptability and packaging reliability in the existing technology, therefore, it is of great practical significance to develop a high-resolution wide-temperature-range metal abrasive particle detection sensitive element and sensor. SUMMARY

[0006] In view of the deficiencies of the prior art, the present application provides a high-resolution wide-temperature-range metal abrasive particle detection sensitive element and sensor to achieve high-resolution detection of ferromagnetic and non-ferromagnetic abrasive particles in a wide temperature range (-40℃ to 200℃) (ferromagnetic metal abrasive particle resolution better than 40μm@14mm, non-ferromagnetic abrasive particle resolution better than 135μm@14mm), and has wide path adaptability (8mm to 27mm), excellent packaging reliability and long service life (average trouble-free working time ≥15000 hours), meeting the wear online detection needs of high-end equipment in the fields of energy, ship, aviation, etc.

[0007] Technical solution: To solve the above technical problems, according to one aspect of the present application, more specifically, a high-resolution wide-temperature-range metal abrasive particle detection sensitive element, the sensitive element is based on a four-coil differential bridge structure design, including two groups of symmetrically distributed coil groups. Each coil group is composed of an excitation coil and a detection coil, and the two coil groups are 180° counter-helically wound on a nanocrystalline soft magnetic core body, and the coil wire diameter is distributed in a gradient, the excitation coil wire diameter is 50-80 μm, and the detection coil wire diameter is 20-35 μm, forming a bidirectional differential detection structure.

[0008] Among them, the nanocrystalline soft magnetic core body adopts Fe73.5Cu1Nb3Si13.5B9 alloy material, is annealed at 300-350℃ for 2 hours, the magnetic permeability is ≥80000, and the saturation magnetic induction intensity is ≥1.2T. The coil group is wound with three layers of insulating enamel wire, the outer layer is a polyimide coating, the temperature resistance is 260℃; the middle layer is a nanoceramic insulation layer, the dielectric strength is ≥100kV / mm; the inner layer is an ultrathin polyurethane layer.

[0009] The present application also provides a high-resolution wide-temperature-range metal abrasive particle detection sensor, which comprises the high-resolution wide-temperature-range metal abrasive particle detection sensitive element, and further comprises a temperature compensation type signal processing module and a metal-ceramic composite packaging structure.

[0010] The temperature compensation type signal processing module comprises a PT1000 temperature sensor and a FPGA dynamic compensation unit, which can correct the magnetic permeability drift in the temperature range of-40℃ to 200℃ in real time. The metal-ceramic composite packaging structure is connected by brazing between the Kovar alloy shell and the 95% Al2O3 ceramic substrate, and is filled with nanographene heat-conducting glue inside, with a thermal conductivity of 15 W / m・K.

[0011] The signal processing module integrates a wavelet packet transform filter circuit, which can extract weak signals with a signal-to-noise ratio of ≤-15dB, and combines a deep learning recognition model, which is trained based on 500,000 groups of abrasive particle samples, to realize an iron magnetic / non-iron magnetic abrasive particle classification accuracy of ≥98%. The packaging structure is provided with an axial stress release groove with a depth of 0.3-0.5mm and a pitch of 2-3mm, and cooperates with an elastic buffer layer made of silicone rubber with a hardness of Shore A 40-50, which can withstand an impact load of 1000g. The sensor diameter adaptation structure adopts a replaceable modular design, including 8mm, 14mm and 27mm three kinds of guide body components, and realizes diameter conversion through a quick plug-in interface.

[0012] The present application has the following advantages:

[0013] (1) The present application adopts two groups of 180° counter-helical coils to form a Wheatstone bridge, when the abrasive particles pass through, the two groups of coils generate phase-opposite induced electromotive forces, greatly improving the resolution of abrasive particle detection.

[0014] (2), the core is prepared by selecting a specific alloy and annealing, the temperature coefficient of magnetic permeability is as low as ≤50ppm / ℃, which is much better than 200ppm / ℃ of the traditional silicon steel sheet, and the runway-shaped cross-section design of the core effectively increases the magnetic field action area, so that the abrasive particle signal capture rate is increased by 40%, and the detection stability in a wide temperature range is ensured.

[0015] (3), the coil in the application adopts special three-layer insulated enameled wire, the outer polyimide coating solves the high-temperature melting problem, the middle nanometer ceramic insulation layer realizes high voltage resistance, and the inner ultra-thin polyurethane layer guarantees low-temperature flexibility, so that the reliability and service life of the coil are significantly improved. BRIEF DESCRIPTION OF DRAWINGS

[0016] The application will be further described in detail below in combination with the drawings and specific implementation methods.

[0017] Figure 1 The figure is a structural schematic diagram of a high-resolution wide-temperature-range metal abrasive particle detection sensitive element in the application. DETAILED DESCRIPTION

[0018] The application will be described in detail below with reference to the drawings and in combination with the embodiments. It should be noted that the embodiments in the application and the features in the embodiments can be combined with each other without conflict.

[0019] In order to make the technical scheme of the application clearer, the application will be further described in detail below in combination with the drawings and specific embodiments.

[0020] Embodiment 1

[0021] Reference Figure 1 A high-resolution wide-temperature-range metal abrasive particle detection sensitive element and an aero-engine application of a sensor:

[0022] Sensitive element preparation: Fe73.5Cu1Nb3Si13.5B9 alloy is processed into a runway-shaped core with a long axis of 10 mm and a short axis of 6 mm, and is annealed at 320℃ for 2 hours. A Φ50μm excitation coil and a Φ25μm detection coil three-layer insulated enameled wire are adopted, and are wound according to 180° reverse spiral, the excitation coil has 200 turns, the detection coil has 500 turns, and a four-coil structure is formed.

[0023] Sensor assembly: the sensitive element and a PT1000 temperature sensor are integrated on a 95% Al2O3 ceramic substrate, are welded to a Kovar alloy shell, and are filled with graphene heat-conducting glue inside. The signal processing module adopts Xilinx Zynq UltraScale+ FPGA, integrates a wavelet packet transform filter circuit, loads a pre-trained CNN-LSTM model, and has an input layer of 128 dimensions and an output layer of 3 classes: ferromagnetic / non-ferromagnetic / non-metal.

[0024] Test results: 100 μm ferromagnetic abrasive particles were detected in aviation kerosene at 200℃, the signal amplitude was 120 μV, the signal-to-noise ratio was 18 dB, and the classification accuracy was 98.7%; after being frozen at-40℃ for 3 hours, 40 μm ferromagnetic abrasive particles were detected with stable signal, and the average failure-free time reached 18,000 hours, which exceeded the index by 20%.

[0025] Example 2

[0026] Reference Figure 1 A high-resolution wide-temperature-range metal abrasive particle detection sensitive element and sensor for deep-sea ship gear box monitoring:

[0027] Pathway adaptation: replace the 27mm flow guide component, the inner wall is plated with a Ni-P antifriction layer with a thickness of 50 μm and a hardness of HV500, and the interface is sealed by an O-ring and a threaded double seal.

[0028] Environmental adaptability test: after 500 cycles of temperature difference from-25℃ to 120℃, the sensor zero drift is less than or equal to 5 μV, and the detection resolution of 135 μm aluminum alloy abrasive particles meets the standard; after 1000g impact test simulating ship pitching, the signal amplitude fluctuation is less than 3%.

[0029] The present application breaks through the technical bottleneck of existing sensors in high-resolution detection in a wide temperature range, and exhibits excellent performance in practical application, and can provide accurate and reliable technical support for the wear condition monitoring of high-end equipment, and has significant engineering application value and broad market prospect.

[0030] The above-described embodiments only express several embodiments of the present application, and the description is more specific and detailed, but it should not be understood as limiting the scope of the present patent. It should be noted that for ordinary skilled persons in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are all within the protection scope of the present application. Therefore, the protection scope of the present patent should be subject to the appended claims.

Claims

1. A high resolution wide temperature range metal abrasive grain detection sensor, characterized in that, Each group of coils consists of an excitation coil and a detection coil, forming a four-coil differential bridge structure; The two groups of coils are oppositely wound on the nanocrystalline soft magnetic core body at an angle of 180°, and the wire diameters are distributed in a gradient manner to realize bidirectional differential detection; The nanocrystalline soft magnetic core body is made of Fe73.5Cu1Nb3Si13.5B9 alloy material, annealed at 300-350℃ for 2 hours, with a magnetic permeability ≥80000 and a saturation magnetic induction intensity ≥1.2T; The coil group is wound with three layers of insulating enamel wire, with a polyimide coating on the outer layer, a nanoceramic insulation layer in the middle layer, and an ultrathin polyurethane layer on the inner layer.

2. A high resolution wide temperature range metal abrasive particle detection sensor comprising a high resolution wide temperature range metal abrasive particle detection sensitive element according to claim 1, characterized in that, It also includes: A temperature compensation signal processing module, which contains a PT1000 temperature sensor and a FPGA dynamic compensation unit, can correct the magnetic permeability drift in the temperature range of-40℃~200℃ in real time; A metal-ceramic composite packaging structure, which is connected by brazing between the Kovar alloy shell and the 95% Al2O3 ceramic substrate, and filled with nanographene thermal conductive glue (thermal conductivity 15W / m・K) inside; The signal processing module integrates a wavelet packet transform filter circuit, which can extract weak signals with a signal-to-noise ratio ≤-15dB, and combined with a deep learning recognition model, realizes the classification accuracy of ferromagnetic / non-ferromagnetic abrasive particles ≥98%; The packaging structure is provided with an axial stress release groove, which can withstand an impact load of 1000g in cooperation with an elastic buffer layer; The sensor passage diameter adaptation structure adopts a replaceable modular design, including 8mm / 14mm / 27mm three specifications of flow guide components, and realizes the conversion of the passage diameter through a quick plug-in interface.

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