Abrasion Powder Sensor Layout to Prevent Electrode Short Circuits
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Solution Overview
Problem
Conventional sensors for detecting abrasion powder in lubricating oil within mechanical devices, such as speed reducers, can malfunction due to foreign matter and fail to accurately sense increased abrasion powder levels, especially in large-size devices, leading to unexpected operations and failure detection issues.
Innovation Solution
A sensor design featuring a first and second electrode with a first attracting portion and a sensitivity adjusting unit, including a separate magnet, to control the attraction of conductive abrasion powder, preventing short circuits and adjusting sensitivity based on expected abrasion powder amounts, ensuring reliable detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional sensor with a single attracting portion is used to detect abrasion powder in large-size mechanical devices, then the sensor can detect increased abrasion powder levels, but the sensor malfunctions due to large amounts of abrasion powder from initial wear causing short circuits
Solution Approach 1:
The single attracting portion is divided into multiple attracting portions (first attracting portion and second attracting portion). The first attracting portion is positioned between the electrodes to attract abrasion powder for detection, while the second attracting portion is positioned elsewhere to attract and remove excess abrasion powder before it can cause short circuits between electrodes. This segmentation allows the sensor to handle large amounts of abrasion powder without malfunctioning.
2Device complexity
If a conventional sensor structure is used, then the device complexity is low, but foreign matter with large particle size causes short circuits between electrodes leading to unexpected sensor operations
Solution Approach 1:
The sensor structure is segmented into multiple functional components: first electrode, second electrode, first attracting portion positioned between the electrodes for detection, and second attracting portion for removing foreign matter. This segmentation enables the sensor to distinguish between abrasion powder for detection and large foreign matter that could cause false readings, improving reliability without excessive complexity.
Solution Approach 2:
The second attracting portion acts as an intermediary component that removes foreign matter with large particle size before it can reach the space between electrodes and cause short circuits. This intermediary structure prevents harmful effects while maintaining the basic sensor functionality.
3Measurement precision
If the sensor allows all abrasion powder to reach the detection region, then detection sensitivity is high, but the sensor cannot distinguish between normal initial wear and abnormal wear requiring maintenance
Solution Approach 1:
The sensor divides the attracting function into two segments: the first attracting portion that allows controlled attraction of abrasion powder for detection between electrodes, and the second attracting portion that removes excess abrasion powder. This segmentation enables the sensor to detect abnormal wear increases while being tolerant of normal initial wear amounts, providing adaptability across different wear stages.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sensor effectively prevents unexpected operations and enhances reliability by accurately sensing abrasion powder levels, even in large-size mechanical devices, allowing for timely maintenance and failure detection.
Implementation Method 1
a magnet for attracting iron powder or the like (a conductive substance) contained in the oil
Implementation Method 2
Based on the resistance between the electrodes, which depends on the conductive substance attracted, the sensor senses the amount of the conductive substance in the oil
Data Source
AI summary
A sensor relating to the present invention includes: a first electrode; a second electrode; a first attracting portion positioned between the first electrode and the second electrode and configured to receive conductive abrasion powder contained in a detection region and attracted onto the first attracting portion; a sensing unit for sensing a change in electrical resistance between the first electrode and the second electrode caused by the conductive abrasion powder; and at least one second attracting portion positioned within the detection region and configured to attract the conductive abrasion powder contained in the detection region.