Fluid Debris Detection With Particle Sizing and Viscosity Sensing
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Solution Overview
Problem
Existing debris detectors in fluid systems, such as gas turbine engines, provide limited quantitative and qualitative information about metal particles in lubricants, leading to unnecessary downtime and manual inspections.
Innovation Solution
A detection system incorporating an inductive sensor, Hall sensor, and capacitive sensor, along with a sensor processing system, to estimate debris particle size, count, and determine lubricant viscosity, providing comprehensive debris and lubricant quality analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If traditional Metal Chip Detectors are used to detect debris particles, then debris detection capability is provided, but quantitative and qualitative information (particle size, total mass, lubricant quality) is not obtained
Solution Approach 1:
The inductive sensor system performs multiple functions: detecting debris particles, estimating particle size, counting particles, and determining lubricant quality through a single integrated sensor assembly. The primary and secondary coils work together to provide both detection and characterization capabilities, eliminating the need for separate sensors for each measurement type.
Solution Approach 2:
The system estimates debris particle size by analyzing changes in the output voltage magnitude signal caused by different particle parameters. By monitoring how debris particles interact with the magnetic field and alter the secondary coil's output, the system derives size information without direct physical measurement of each particle.
2Measurement precision
If manual inspections and laboratory analyses are performed to obtain comprehensive debris information, then detailed particle analysis is achieved, but system downtime increases from weeks to months
Solution Approach 1:
The patent replaces manual inspection procedures and laboratory analysis systems with an automated inductive sensor system. The sensor continuously monitors debris particles in real-time, providing precise measurements of particle presence, size estimation, and counting without requiring physical removal of samples for laboratory examination.
Solution Approach 2:
The inductive sensor system provides continuous real-time monitoring of debris particles as they pass through the lubricant flow, rather than periodic manual sampling. This continuous measurement capability ensures ongoing protection and information gathering without interrupting system operation, eliminating the need for repeated shutdowns for inspection.
3Reliability
If frequent manual inspections are conducted to monitor debris, then system protection is maintained, but productivity decreases due to repeated downtimes
Solution Approach 1:
The sensor system autonomously monitors debris particles and provides continuous information about particle presence, size, and quantity without requiring manual intervention. The system self-regulates by continuously measuring the output voltage magnitude changes caused by debris interactions with the magnetic field, providing ongoing protection without human involvement.
Solution Approach 2:
The system provides continuous feedback about debris particle conditions through real-time measurement of output voltage magnitude variations. This feedback mechanism allows operators to monitor particle accumulation, size distribution, and lubricant quality continuously, enabling timely maintenance decisions that protect the system while minimizing unnecessary shutdowns.
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 real-time, quantitative and qualitative assessment of debris particles, reducing unnecessary inspections and downtime by offering detailed particle and lubricant data.
Implementation Method 1
The magnet produces a magnetic field
Implementation Method 2
magnetically attracts at least a portion of the fine metal debris particles
Implementation Method 3
The primary coil is coupled to receive an excitation signal and is configured, upon receipt of the excitation signal, to generate a primary magnetic flux
Implementation Method 4
The secondary coil is inductively coupled to the primary coil upon electrical excitation of the primary coil and is configured to supply a sensor output signal having an output voltage magnitude that varies each time a debris particle in the fluid interacts with the magnetic field
Implementation Method 5
The Hall sensor is disposed adjacent to the magnet and is configured to supply a Hall sensor output signal proportional to a sensed magnetic field strength
Data Source
AI summary
A detection system for detecting debris in a fluid may include one or more of an inductive sensor, a Hall sensor, a capacitive sensor, and a sensor processing system. The sensor processing, using the signals supplied from the one or more sensors, may do one or more of estimate a size of each debris that has interacted with the magnet field, determine a total number of debris particles that have interacted with the magnet field, determine a cumulative quantity of the debris particles attracted by and contacting the magnet, and determine the viscosity of the fluid.