A portable oil online monitoring system

Abstract

This invention relates to the field of online equipment condition monitoring technology, and in particular to a portable online lubricating oil monitoring system. The system includes an oil inlet, a honeycomb rectifier, an observation section, an oil pump, an oil outlet, an optical observation module, a data acquisition controller, and a data processing and display module. The oil pump sequentially draws lubricating oil from the equipment under test through the oil inlet, honeycomb rectifier, observation section, oil pump, and oil outlet. A CCD camera captures images of large particles (over 100 micrometers) and scattered light images of small particles (1-100 micrometers) in the lubricating oil. These images are then sent to the data processing and display module for analysis to obtain morphological parameters, particle size distribution data, and the current wear type, which are then displayed. This invention discloses the simultaneous realization of morphological imaging of large particles (over 100 micrometers) and particle size distribution detection of small particles (1-100 micrometers) through two-mode switching of a single CCD camera, filling the gap in online monitoring of small particles and enabling earlier detection of wear signs.

Description

Technical Field

[0001] This invention relates to the field of online equipment status monitoring technology, and in particular to a portable online lubricating oil monitoring system. Background Technology

[0002] In the lubrication systems of mechanical equipment, monitoring lubricating oil abrasive particles is crucial for ensuring safe operation. Currently, online lubricating oil monitoring technology is already in use; for example, long-focal-length macro cameras are employed to image and detect particles in the lubricating oil, acquiring particle images and identifying the morphological characteristics of large particles to determine the type of wear. However, the detection accuracy of existing online monitoring equipment is generally limited, typically only able to detect particles larger than 100 micrometers, and unable to effectively monitor particles smaller than 100 micrometers.

[0003] Although these tiny particles are small in size, they have a significant impact on equipment operation: 1) They can participate in the friction process again, generating new wear and creating a vicious cycle; 2) They may puncture the lubricating oil film, reducing lubrication effectiveness; 3) Iron particles can also catalyze the oxidation of lubricating oil, accelerating the consumption of antioxidants and anti-wear agents; 4) The heat generated by friction may also cause localized overheating, leading to faster equipment damage. Because these tiny particles cannot be detected, the true wear condition cannot be grasped, making timely warnings difficult. Often, by the time abnormalities are discovered, the equipment has already been severely damaged.

[0004] In addition, existing online monitoring systems have the following problems: First, traditional detection equipment can usually only detect large particles larger than 100 micrometers and cannot effectively monitor small particles of 1-100 micrometers. It lacks comprehensive detection capability for the entire particle size range of abrasive particles (from micrometers to millimeters), making it difficult to detect early wear. Second, existing equipment mostly uses independent camera modules and laser particle size analyzers, which are bulky, inconvenient to carry, and not easy to quickly deploy to different detection points on site for multi-point wear location analysis. Third, existing systems are usually fixed in a certain position on the equipment, making it impossible to selectively monitor different modules of the equipment and difficult to accurately locate the wear parts.

[0005] Therefore, there is an urgent need in this field for an online lubricating oil monitoring system that can simultaneously detect large and small particles, is portable, easy to use, and can be flexibly deployed. Summary of the Invention

[0006] The purpose of this invention is to provide a portable online lubricating oil monitoring system that can simultaneously detect large and small particles, is easy to carry, and is simple to use.

[0007] To achieve the above objectives, the present invention provides a portable online lubricating oil monitoring system, the system comprising:

[0008] An oil inlet is connected to the device under test and is used to extract lubricating oil from the device under test.

[0009] A honeycomb rectifier, connected to the oil inlet, is used to adjust the flowing lubricating oil to a laminar flow state;

[0010] The observation section, connected to the cellular rectifier, is used to display the lubricating oil flow;

[0011] The oil outlet is connected to the device under test.

[0012] An oil pump is connected to the observation section and the oil outlet respectively, and is used to pump lubricating oil into the device under test through the oil outlet to form a closed loop circulation.

[0013] A light source, corresponding to the observation section, is provided to provide uniform illumination;

[0014] An optical observation module is provided corresponding to the observation section. The optical observation module is an integrated structure consisting of a laser and a CCD camera. When the light source is turned on and the laser is turned off, the CCD camera is used to capture images of large particles larger than 100 micrometers in the lubricating oil, referred to as the first image. When the laser is turned on and the light source is turned off, the CCD camera is used to capture the scattered light generated after the laser irradiates the particles within a certain angle range to obtain the second image.

[0015] An acquisition controller, connected to the CCD camera, is used to acquire the first image and the second image, and to package the data.

[0016] The data processing and display module, connected to the acquisition controller, is used to analyze and process the packaged data to obtain morphological parameters, particle size distribution data, and current wear type, and then display them.

[0017] Optionally, the system includes:

[0018] A first connecting segment is disposed between the cellular rectifier and the observation segment for transitional connection between the cellular rectifier and the observation segment;

[0019] The second connecting section is disposed between the observation section and the oil pump, and is used to transitionally connect the observation section and the oil pump.

[0020] Optionally, the system further includes:

[0021] A flow meter is connected in series in the pipeline between the second connecting section and the oil pump, and is connected to the acquisition controller. It is used to monitor the lubricating oil flow and send it to the acquisition controller so that the acquisition controller can determine when the lubricating oil flow deviates from the set value. Then, through a feedback control algorithm, it controls the oil pump speed according to the feedback of the lubricating oil flow to restore the lubricating oil flow to the set value.

[0022] Optionally, the data processing and display module specifically includes:

[0023] The host computer, connected to the acquisition controller, is used to receive packaged data sent by the acquisition controller, and sequentially perform grayscale conversion, filtering, binarization, contour extraction, and morphological parameter calculation on the first image acquired in the first mode to obtain the contour extraction feature map and morphological parameters corresponding to large particles larger than 100 micrometers; the host computer is also used to combine the spatial distribution information of scattered light on the second image, and calculate the particle size distribution data corresponding to small particles of 1 micrometer to 100 micrometers in lubricating oil based on the Mie scattering theory inversion algorithm or the pre-calibrated scattered light intensity-particle size relationship curve.

[0024] Optionally, the data processing and display module further includes:

[0025] The lower-level machine, connected to the upper-level machine, is used to receive the contour extraction feature map and morphological parameters corresponding to large particles larger than 100 micrometers and the particle size distribution data corresponding to small particles from 1 micrometer to 100 micrometers uploaded by the upper-level machine, and to comprehensively determine the current wear type based on the morphological parameters corresponding to large particles and the particle size distribution data corresponding to small particles; the lower-level machine is also used to determine the particle size distribution histogram based on the contour extraction feature map.

[0026] The PC terminal is connected to the lower-level machine and is used to receive and display the contour extraction feature map, particle size distribution histogram, morphological parameters, particle size distribution data and current wear type uploaded by the lower-level machine.

[0027] Optionally, the step of comprehensively determining the current wear type based on the morphological parameters corresponding to large particles and the particle size distribution data corresponding to small particles specifically includes:

[0028] The morphological parameters include: roundness, aspect ratio, and convexity; the particle size distribution data includes: the percentage of particles in each interval and the D50 value.

[0029] If the roundness is greater than 0.8 and the particle surface is smooth, it is determined to be fatigue wear; if the aspect ratio is greater than 3 and the edges are straight, it is determined to be cutting wear; if the convexity is less than 0.7 and the shape is irregular, it is determined to be delamination wear; if the concentration of small particles in the 1-10μm range continues to increase and the D50 value decreases, it is determined to be early wear aggravation.

[0030] Optionally, the system further includes:

[0031] A sensor module is connected in series in the pipeline between the flow meter and the oil pump and is connected to the acquisition controller. It is used to monitor the lubricating oil parameters and send the lubricating oil parameters to the PC terminal for display in sequence through the acquisition controller, the host computer and the slave computer.

[0032] Optionally, the sensor module includes:

[0033] A temperature sensor, connected to the acquisition controller, is used to monitor the temperature of the lubricating oil;

[0034] A pH sensor, connected to the acquisition controller, is used to monitor the pH of the lubricating oil.

[0035] A moisture sensor, connected to the acquisition controller, is used to monitor the moisture content of the lubricating oil.

[0036] Optionally, the acquisition controller packages the collected lubricating oil flow rate, lubricating oil parameters, first image, and second image by adding timestamps and sensor IDs.

[0037] Optionally, the oil inlet and the oil outlet are respectively connected to the two ends of the first functional module of the device under test to obtain the morphological data and particle size distribution data corresponding to the first functional module, and then the connection is disconnected; the oil inlet and the oil outlet are connected to the two ends of the second functional module of the device under test to obtain the morphological data and particle size distribution data corresponding to the second functional module again; by comparing the test results of different modules, the specific location of wear can be accurately located.

[0038] According to specific embodiments provided by the present invention, the present invention discloses the following technical effects:

[0039] This invention discloses a portable online lubricating oil monitoring system, comprising an oil inlet, a honeycomb rectifier, an observation section, an oil pump, an oil outlet, an optical observation module, a data acquisition controller, and a data processing and display module. The oil pump sequentially draws lubricating oil from the device under test through the oil inlet, honeycomb rectifier, observation section, oil pump, and oil outlet. A CCD camera captures images of large particles (over 100 micrometers) and scattered light images of small particles (1-100 micrometers) in the lubricating oil. These images are then sent to the data processing and display module for analysis to obtain morphological parameters, particle size distribution data, and the current wear type, which are then displayed. This invention utilizes a single CCD camera with two modes to simultaneously achieve morphological imaging of large particles (over 100 micrometers) and particle size distribution detection of small particles (1-100 micrometers), filling the gap in online monitoring of small particles and enabling earlier detection of wear signs. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1This is a structural connection diagram of the portable online lubricating oil monitoring system according to an embodiment of the present invention;

[0042] Figure 2 This is a physical image of the portable online lubricating oil monitoring system according to an embodiment of the present invention;

[0043] Among them, 1. Oil inlet, 2. Honeycomb rectifier, 3. First connecting section, 4. Observation section, 5. Second connecting section, 6. Oil pump, 7. Oil outlet, 8. Data processing and display module, 81. Host computer, 82. Sub-computer, 83. PC terminal, 9. Device under test, 10. Flow meter, 11. Sensor module, 12. Data acquisition controller. Detailed Implementation

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] The purpose of this invention is to provide a portable online lubricating oil monitoring system that can simultaneously detect large and small particles, is easy to carry, and is simple to use.

[0046] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0047] like Figures 1-2 As shown, this invention discloses a portable online lubricating oil monitoring system. The system includes: an oil inlet 1, a honeycomb rectifier 2, a first connecting section 3, an observation section 4, a second connecting section 5, an oil pump 6, and an oil outlet 7. One end of the device under test 9 is connected to the oil inlet 1, and the other end of the device under test 9 is connected to the oil outlet 7. The oil inlet 1 is sequentially connected to the honeycomb rectifier 2, the first connecting section 3, the observation section 4, the second connecting section 5, the oil pump 6, and the oil outlet 7. The oil inlet 1 is used to extract lubricating oil from the device under test 9. The honeycomb rectifier 2 is used to adjust the flowing lubricating oil to a laminar flow state. The first connecting section 3 is used to transition between the honeycomb rectifier 2 and the observation section 4. The observation section 4 is used to display the lubricating oil flow. The second connecting section 5 is used to transition between the observation section 4 and the oil pump 6. The oil pump 6 is used to pump the lubricating oil into the device under test 9 through the oil outlet 7, forming a closed-loop circulation that does not affect the normal operation of the equipment.

[0048] The observation section 4 of this invention is a square pipe made of a transparent material (such as glass or quartz), which facilitates subsequent observation of the lubricating oil flow process through the transparent material. The honeycomb rectifier 2 is installed inside the pipe behind the oil inlet 1 and consists of multiple honeycomb-shaped holes. It is used to rectify the flowing lubricating oil from a turbulent state to a stable laminar state, thereby reducing the interference of turbulence on particle detection. The first connecting section 3 and the second connecting section 5 are used to ensure a smooth fluid transition; specifically, the first connecting section 3 is a transition joint from round to square, with its front end connected to a round pipe and its rear end connected to the square inlet of the observation section 4; the second connecting section 5 is a transition joint from square to round, with its front end connected to the square outlet of the observation section 4 and its rear end connected to a round pipe; the oil pump 6 serves as a power unit to drive the lubricating oil to circulate in the loop; the type of oil pump 6 can be a micro gear pump or a peristaltic pump to adapt to the power consumption and space requirements of portable devices.

[0049] As an optional implementation, the present invention also requires a housing. The oil inlet 1, honeycomb rectifier 2, first connecting section 3, observation section 4, second connecting section 5, oil pump 6, and oil outlet 7 are all housed inside the portable housing. This not only protects the aforementioned components but also facilitates carrying the structure. Furthermore, the housing is equipped with an oil inlet interface, an oil outlet interface, a power interface, and a data communication interface for easy on-site carrying and quick connection. The power interface provides power to the oil pump 6; the data communication interface is used for data communication with an external server, uploading at least one of the following data: lubricating oil parameters, lubricating oil flow rate, particle concentration, particle size distribution histogram, current wear type, and wear location. The housing is designed for easy hand-holding or placement in a toolbox, for example, its length, width, and height do not exceed 300mm × 200mm × 150mm.

[0050] As an optional implementation, the present invention also requires an optical observation module and a light source. The optical observation module integrates a laser and a CCD camera into a single structure, with the laser, light source, and CCD camera all corresponding to observation section 4. The light source provides uniform illumination to ensure clear images. The laser emits a parallel beam to irradiate the lubricating oil sample flowing through observation section 4. The particles scatter the laser light, generating scattered light, the intensity of which is related to the particle size. The optical observation module has two operating modes: the first mode is with the light source on and the laser off, in which case the CCD camera is used as a long-focal-length macro camera to capture images of large particles larger than 100 micrometers in the lubricating oil, referred to as the first image; the second mode is with the laser on and the light source off, in which the CCD camera captures the scattered light generated after the laser irradiates the particles within a certain angle range to obtain the second image. The laser and CCD camera disclosed in this invention are both located outside the housing. The laser and CCD camera can be integrated or separately; the present invention preferably integrates them, reducing the overall size of the device and thus making it easy to carry. The light source is located inside the housing and is controlled by a switch.

[0051] The CCD camera of this invention acquires a first image corresponding to large particles larger than 100 micrometers in a first mode and a second image corresponding to small particles from 1 to 100 micrometers in a second mode. Together, they constitute a full particle size detection range from micrometers to millimeters. By switching between the two modes, the CCD camera simultaneously realizes the functions of large particle imaging and small particle imaging, significantly reducing the system size and cost.

[0052] As an optional implementation, the present invention can also be configured with a flow meter 10 and a sensor module 11, which are disposed between the second connecting section 5 and the oil pump 6. The flow meter 10 is used to monitor the lubricating oil flow rate so that the rotational speed of the oil pump 6 can be controlled according to the lubricating oil flow rate feedback to maintain a constant flow rate, thereby ensuring the consistency of particle detection conditions and improving detection repeatability. The sensor module 11 is used to monitor lubricating oil parameters.

[0053] As an optional implementation, the sensor module 11 of the present invention includes, but is not limited to, a temperature sensor, a pH sensor, and a moisture sensor, connected in series in the oil circuit; the temperature sensor, pH sensor, and moisture sensor are used to collect the temperature, pH, and moisture content of the lubricating oil, respectively. The lubricating oil parameters include, but are not limited to, the temperature, pH, and moisture content of the lubricating oil. In this embodiment, the temperature sensor can be a platinum resistance thermometer (Pt100), with a measurement range of -20℃ to 150℃; the moisture sensor can be capacitive, with a measurement range of 0-100% relative saturation; and the pH sensor can be a pH electrode, with a measurement range of 0-14 pH. All three sensors have temperature compensation functionality.

[0054] As an optional implementation, the present invention can also be configured with a data acquisition controller 12, which is connected to the flow meter 10, the sensor module 11, and the CCD camera respectively. The controller is used to acquire lubricating oil flow rate, lubricating oil parameters, a first image, and a second image, and to perform data format conversion, time synchronization, and data packaging. The packaged data is then transmitted to the host computer 81 via wired or wireless means. In this embodiment, the data acquisition controller 12 uses a microcontroller (e.g., STM32) with a built-in analog-to-digital converter and multiple serial interfaces. The data acquisition controller 12 is connected to the flow meter 10, the CCD camera, the temperature sensor, the pH sensor, and the moisture sensor via RS485 or CAN bus, respectively, to collect lubricating oil flow rate, lubricating oil parameters, the first image, and the second image at a sampling frequency of 1Hz to 10Hz, and to package the data (adding timestamps and sensor IDs). The data acquisition controller 12 communicates with the host computer 81 via Ethernet or USB to upload the packaged data in real time.

[0055] As an optional implementation, the data acquisition controller 12 of the present invention is also connected to the oil pump 6. When the lubricating oil flow rate deviates from the set value, it uses a feedback control algorithm to control the rotation speed of the oil pump 6 based on the lubricating oil flow rate feedback, so that the lubricating oil flow rate returns to the set value. This function ensures the consistency of particle detection conditions and improves the repeatability of detection. For example, the flow rate can be set to 100 ml / min, the flow meter 10 reads the flow rate value every 0.1 seconds, and the PWM duty cycle of the oil pump 6 is adjusted through a PID algorithm to keep the actual flow rate within ±5% of the set value.

[0056] As an optional implementation, the present invention can also be configured with a data processing and display module 8, which includes a host computer 81 and a slave computer 82. The host computer 81 is connected to the slave computer 82 and the acquisition controller 12, respectively, and is used to receive packaged data sent by the acquisition controller 12. Based on the first image acquired in the first mode, it sequentially performs grayscale conversion, filtering, binarization, contour extraction, and morphological parameter calculation to obtain contour extraction feature maps and morphological parameters. The morphological parameters include the roundness, aspect ratio, and convexity of the particles. The spatial distribution of scattered light in the present invention is related to the particle size, the intensity of scattered light is directly proportional to the particle size, and the scattering angle is inversely proportional to the particle size. Therefore, the host computer 81, combined with the spatial distribution information of scattered light on the second image, calculates the particle size distribution data of small particles from 1 micrometer to 100 micrometers in the lubricating oil based on the Mie scattering theory inversion algorithm or a pre-calibrated scattered light intensity-particle size relationship curve. The particle size distribution data includes the percentage of particles in each particle size range, the volume ratio, and the cumulative distribution curve. This invention can divide particle size into five intervals: 1-5μm, 5-10μm, 10-20μm, 20-50μm, and 50-100μm, and calculate the percentage of particles in each interval. The host computer 81 integrates lubricating oil flow rate, lubricating oil parameters, contour extraction feature map, morphological parameters, and particle size distribution data into a comprehensive feature vector, which is then transmitted to the slave computer 82. In this embodiment, the host computer 81 is an industrial-grade embedded industrial control computer or a general-purpose computer.

[0057] The lower-level 82 uses an ARM processor and incorporates wear diagnosis and location analysis algorithms. The wear diagnosis algorithm determines the current wear type based on the morphological parameters of large particles (e.g., roundness, aspect ratio, and convexity) and the particle size distribution data of small particles (e.g., the proportion of particles in each range and the D50 value). For example: if the roundness is greater than 0.8 and the particle surface is smooth, it is determined to be fatigue wear; if the aspect ratio is greater than 3 and the edges are straight, it is determined to be cutting wear; if the convexity is less than 0.7 and the shape is irregular, it is determined to be delamination wear; if the concentration of small particles (1-10μm range) continues to increase and the D50 value decreases, it is determined to be early wear aggravation. All wear particles in the lubricating oil are sorted by particle size from smallest to largest, and the 50% dividing line particle size is represented by D50.

[0058] The location analysis algorithm leverages the system's portability and ease of disassembly and reconnection to perform wear localization. For example, oil inlet 1 and oil outlet 7 are connected to the two ends of the first functional module (e.g., gearbox A) of the device under test 9 to obtain the corresponding morphological and particle size distribution data. Then, the connection is disconnected, and oil inlet 1 and oil outlet 7 are connected to the two ends of the second functional module (e.g., bearing B) of the same device to obtain the corresponding morphological and particle size distribution data again. By comparing the detection results of different modules (e.g., particle concentration, wear type, particle size distribution), the specific location of wear can be accurately located.

[0059] The lower-level machine 82 is also used to determine the particle size distribution histogram based on the contour extraction feature map; and to transmit the lubricating oil flow rate, lubricating oil parameters, contour extraction feature map, particle size distribution histogram, morphological parameters, particle size distribution data, current wear type and wear location to the PC terminal 83.

[0060] As an optional implementation, the data processing and display module 8 of the present invention further includes a PC terminal 83, which is connected to the lower-level computer 82. The PC terminal 83 is equipped with monitoring software for displaying at least one of the following: lubricating oil temperature, moisture content, pH, temperature, profile extraction feature map, particle size distribution histogram, morphological parameters, particle size distribution data, current wear type, and wear location. Some of the above data can be displayed in real time using a graphical interface. When an anomaly is detected (e.g., particle concentration exceeding a threshold, abnormal particle morphology, temperature or pH exceeding the normal range), the PC terminal 83 automatically pops up an alarm window and issues an audible alert, while simultaneously storing the alarm information in a local database to remind operators to perform timely maintenance.

[0061] As an optional implementation, the data acquisition controller 12, the lower-level machine 82, the upper-level machine 81, and the PC terminal 83 are respectively installed in the circuit board cavity inside the housing, completely isolated from the oil circuit.

[0062] System Workflow: Oil pump 6 is activated, drawing lubricating oil from the device under test 9. The oil flows sequentially through the honeycomb rectifier 2, first connecting section 3, observation section 4, second connecting section 5, flow meter 10, and sensor module 11 at a flow rate of approximately 50-200 ml / min, then is pumped back to the device under test 9 by oil pump 6, forming a continuous cycle. During this cycle, the CCD camera's operating mode is switched as needed: to observe large particle morphology, the light source is turned on and the laser is turned off, continuously capturing images; to analyze small particle size distribution, the laser is turned on and the light source is turned off, continuously collecting scattered light. The data acquisition unit polls all sensors at a frequency of 1 Hz, packaging and uploading the data to the host computer 81. The host computer 81 generates a comprehensive feature vector every 10 seconds and sends it to the slave computer 82. The slave computer 82 updates the wear diagnosis and positioning results every 10 seconds and sends them to the PC terminal 83. The PC terminal 83 refreshes the display interface in real time. When an anomaly is detected, the system immediately issues a warning.

[0063] This embodiment integrates a traditionally separate camera module and a laser particle size analyzer into an optical observation module by designing the CCD camera to have dual-mode switching. Combined with a cellular rectifier 2, flow feedback control, multi-parameter sensors, and a portable housing, it achieves full particle size coverage, portable integration, and wear location functions. This enables earlier detection of wear signs and more accurate determination of wear type and location, improving the practicality and timeliness of on-site lubricating oil monitoring.

[0064] Compared with the prior art, the present invention has the following beneficial effects:

[0065] Full particle size coverage: This invention uses a single CCD camera to switch between two modes. In the first mode, the first image corresponding to large particles larger than 100 micrometers is used to determine the contour shape characteristics, wear type, and wear degree of the particles. In the second mode, the second image corresponding to small particles of 1-100 micrometers is used to assess the early wear degree, wear type, and particle concentration change trend. The two complement each other to achieve online monitoring of the full particle size of lubricating oil abrasive particles, filling the gap in online monitoring of small particles and enabling earlier detection of wear signs.

[0066] Portable integration: The independent camera module and laser particle size analyzer in the traditional system are integrated into an optical observation module. Combined with a micro oil pump 6 and a compact sensor, the whole is integrated into a portable housing. It is small in size and light in weight, making it easy to carry and deploy in the field.

[0067] Wear location: Taking advantage of the system's portability, it can be connected to both ends of different functional modules of the equipment in sequence. By comparing the test results, the specific location of wear can be located, providing precise guidance for maintenance.

[0068] Flow rate control: The speed of oil pump 6 is controlled by feedback from flow meter 10 to maintain a constant flow rate, which improves the repeatability and reliability of the test results.

[0069] Multi-parameter fusion: By combining particle information with multiple parameters such as temperature, pH, and moisture, the wear type and degree can be comprehensively judged, resulting in higher diagnostic accuracy.

[0070] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to the method section.

[0071] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A portable online lubricating oil monitoring system, characterized in that, The system includes: An oil inlet is connected to the device under test and is used to extract lubricating oil from the device under test. A honeycomb rectifier, connected to the oil inlet, is used to adjust the flowing lubricating oil to a laminar flow state; The observation section, connected to the cellular rectifier, is used to display the lubricating oil flow; The oil outlet is connected to the device under test. An oil pump is connected to the observation section and the oil outlet respectively, and is used to pump lubricating oil into the device under test through the oil outlet to form a closed loop circulation. A light source, corresponding to the observation section, is provided to provide uniform illumination; An optical observation module is provided corresponding to the observation section. The optical observation module is an integrated structure consisting of a laser and a CCD camera. When the light source is turned on and the laser is turned off, the CCD camera is used to capture images of large particles larger than 100 micrometers in the lubricating oil, referred to as the first image. When the laser is turned on and the light source is turned off, the CCD camera is used to capture the scattered light generated after the laser irradiates the particles within a certain angle range to obtain the second image. An acquisition controller, connected to the CCD camera, is used to acquire the first image and the second image, and to package the data. The data processing and display module, connected to the acquisition controller, is used to analyze and process the packaged data to obtain morphological parameters, particle size distribution data, and current wear type, and then display them.

2. The portable online lubricating oil monitoring system according to claim 1, characterized in that, The system includes: A first connecting segment is disposed between the cellular rectifier and the observation segment for transitional connection between the cellular rectifier and the observation segment; The second connecting section is disposed between the observation section and the oil pump, and is used to transitionally connect the observation section and the oil pump.

3. The portable online lubricating oil monitoring system according to claim 2, characterized in that, The system also includes: A flow meter is connected in series in the pipeline between the second connecting section and the oil pump, and is connected to the acquisition controller. It is used to monitor the lubricating oil flow and send it to the acquisition controller so that the acquisition controller can determine when the lubricating oil flow deviates from the set value. Then, through a feedback control algorithm, it controls the oil pump speed according to the feedback of the lubricating oil flow to restore the lubricating oil flow to the set value.

4. The portable online lubricating oil monitoring system according to claim 3, characterized in that, The data processing and display module specifically includes: The host computer, connected to the acquisition controller, is used to receive packaged data sent by the acquisition controller, and sequentially perform grayscale conversion, filtering, binarization, contour extraction, and morphological parameter calculation on the first image acquired in the first mode to obtain the contour extraction feature map and morphological parameters corresponding to large particles larger than 100 micrometers; the host computer is also used to combine the spatial distribution information of scattered light on the second image, and calculate the particle size distribution data corresponding to small particles of 1 micrometer to 100 micrometers in lubricating oil based on the Mie scattering theory inversion algorithm or the pre-calibrated scattered light intensity-particle size relationship curve.

5. The portable online lubricating oil monitoring system according to claim 4, characterized in that, The data processing and display module further includes: The lower-level machine, connected to the upper-level machine, is used to receive the contour extraction feature map and morphological parameters corresponding to large particles larger than 100 micrometers and the particle size distribution data corresponding to small particles from 1 micrometer to 100 micrometers uploaded by the upper-level machine, and to comprehensively determine the current wear type based on the morphological parameters corresponding to large particles and the particle size distribution data corresponding to small particles; the lower-level machine is also used to determine the particle size distribution histogram based on the contour extraction feature map. The PC terminal is connected to the lower-level machine and is used to receive and display the contour extraction feature map, particle size distribution histogram, morphological parameters, particle size distribution data and current wear type uploaded by the lower-level machine.

6. The portable online lubricating oil monitoring system according to claim 5, characterized in that, The method of comprehensively determining the current wear type based on the morphological parameters of large particles and the particle size distribution data of small particles specifically includes: The morphological parameters include: roundness, aspect ratio, and convexity; the particle size distribution data includes: the percentage of particles in each interval and the D50 value. If the roundness is greater than 0.8 and the particle surface is smooth, it is determined to be fatigue wear; if the aspect ratio is greater than 3 and the edges are straight, it is determined to be cutting wear; if the convexity is less than 0.7 and the shape is irregular, it is determined to be delamination wear; if the concentration of small particles in the 1-10μm range continues to increase and the D50 value decreases, it is determined to be early wear aggravation.

7. The portable online lubricating oil monitoring system according to claim 5, characterized in that, The system also includes: A sensor module is connected in series in the pipeline between the flow meter and the oil pump and is connected to the acquisition controller. It is used to monitor the lubricating oil parameters and send the lubricating oil parameters to the PC terminal for display in sequence through the acquisition controller, the host computer and the slave computer.

8. The portable online lubricating oil monitoring system according to claim 7, characterized in that, The sensor module includes: A temperature sensor, connected to the acquisition controller, is used to monitor the temperature of the lubricating oil; A pH sensor, connected to the acquisition controller, is used to monitor the pH of the lubricating oil. A moisture sensor, connected to the acquisition controller, is used to monitor the moisture content of the lubricating oil.

9. The portable online lubricating oil monitoring system according to claim 8, characterized in that, The acquisition controller packages the collected lubricating oil flow rate, lubricating oil parameters, first image, and second image by adding timestamps and sensor IDs.

10. The portable online lubricating oil monitoring system according to claim 8, characterized in that, Connect the oil inlet and the oil outlet to the two ends of the first functional module of the device under test, respectively, to obtain the morphological data and particle size distribution data corresponding to the first functional module, and then disconnect them; connect the oil inlet and the oil outlet to the two ends of the second functional module of the device under test, and obtain the morphological data and particle size distribution data corresponding to the second functional module again; by comparing the test results of different modules, accurately locate the specific location where wear occurs.

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