Fluid Contamination Sensor with Gas Separation
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Solution Overview
Problem
Current particle detection methods in hydraulic systems are unreliable due to interference from non-solid foreign substances like air bubbles and oil aging products, leading to false readings and premature oil replacement, as they cannot distinguish between actual particle contamination and other contaminants.
Innovation Solution
A device with a sample preparation section that separates gaseous media and includes additional devices for detecting and separating non-fluid contaminants, allowing the particle sensor to focus on solid particle contamination without interference, using components like air separators, filters, and temperature control to improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If particle sensors are used to detect foreign substances in hydraulic fluid, then the number of particles can be determined, but non-solid contaminants like air bubbles and oil aging products cause false readings and reduce measurement precision
Solution Approach 1:
The device segments the detection process by separating solid particle detection from non-solid contaminant detection. A sample preparation section with air separators and filters removes air bubbles and liquid contaminants before the fluid reaches the particle sensor, while separate sensors detect non-solid contaminants. This segmentation allows each sensor to focus on its specific target without interference.
Solution Approach 2:
The invention extracts and removes non-solid contaminants (air bubbles and liquid contaminants) from the hydraulic fluid before particle detection. The air separator removes dissolved and dispersed air, while filters remove liquid contaminants. This extraction eliminates the harmful interference these contaminants cause to particle sensor measurements.
2Reliability
If filter systems are used to remove particle contamination, then particle entry into hydraulic fluid is reduced, but filter blockage can occur leading to bypass device activation and increased particle contamination
Solution Approach 1:
The device implements continuous online particle detection that provides real-time feedback about contamination levels. When particle counts indicate filter bypass contamination, the system can alert operators to replace filters before blockage occurs, preventing the harmful cycle of bypass activation and increased contamination.
Solution Approach 2:
The sample preparation section performs preliminary cleaning of the hydraulic fluid by removing air bubbles and liquid contaminants before the fluid enters the particle sensor. This preliminary action ensures that only solid particles are detected, eliminating false readings and enabling accurate monitoring of actual particle contamination levels.
3Productivity
If optical particle sensors are used for online particle detection, then measurement results are available directly, but the sensors cannot distinguish between solid particles and other contaminants like air bubbles
Solution Approach 1:
The device segments the detection process by separating solid particle detection from non-solid contaminant detection. A sample preparation section with air separators and filters removes air bubbles and liquid contaminants before the fluid reaches the particle sensor, while separate sensors detect non-solid contaminants. This segmentation allows each sensor to focus on its specific target without interference.
Solution Approach 2:
The sample preparation section acts as an intermediary between the hydraulic fluid and the particle sensor. It pre-treats the fluid by removing air bubbles and liquid contaminants, so that when the fluid reaches the optical particle sensor, only solid particles remain. This intermediary preparation enables the sensor to accurately detect and count only solid particles without being misled by other contaminants.
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
Enables precise detection of even fine particles with diameters greater than 14 μm, distinguishing between solid particles and other contaminants, reducing false positives and allowing for targeted maintenance of hydraulic systems by accurately assessing particle contamination.
Implementation Method 1
a sample preparation section (7) which can be connected to the measuring section (3) by means of a connecting device (9) to carry fluid, in particular in the form of a sample container (29), for separating the gaseous medium from the measuring section (3) while calming the fluid taken up
Implementation Method 2
Under the mentioned optical measurement method, the electronic analysis is addressed by light shading, which is also referred to as the extinction method in technical terms. This electronic analysis counts the particles via an optical sensor. The light beam from the optical sensor is more or less shadowed depending on the size of the particles.
Implementation Method 3
The known sensor device according to the cited WO publication uses an inductive particle counter for this purpose, with the device having at least one field coil for generating a magnetic field that covers the fluid flow at least in sections and having a sensor coil which is connected to an electronic evaluation device, by means of which from the Sensor coil induced signal determines or detects the presence of a particle in the fluid flow
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a device for determining foreign substances such as particulates in fluids which, in addition to this particulate matter, can also have contaminants extraneous to the fluid, such as solid, liquid and gaseous foreign substances, the device comprising a measurement path (3) having a particulate sensor (5) for determining the particulate matter. The device is characterized in that a sample preparation path (7) can be connected by means of a connecting device (9) to the measurement path (3) so as to conduct fluid and in that the sample processing path (7) has at least one additional device (11) for determining the respective other contamination extraneous to the fluid and/or for at least partially separating it from the fluid.