CN113035565B - Working solution metal particle detection equipment and coil manufacturing method thereof - Google Patents
Working solution metal particle detection equipment and coil manufacturing method thereof Download PDFInfo
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- CN113035565B CN113035565B CN202110261524.6A CN202110261524A CN113035565B CN 113035565 B CN113035565 B CN 113035565B CN 202110261524 A CN202110261524 A CN 202110261524A CN 113035565 B CN113035565 B CN 113035565B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume, or surface-area of porous materials
- G01N15/02—Investigating particle size or size distribution
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
- G01V3/00—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation
- G01V3/08—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices
- G01V3/10—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices using induction coils
- G01V3/104—Electric or magnetic prospecting or detecting; Measuring magnetic field characteristics of the earth, e.g. declination, deviation operating with magnetic or electric fields produced or modified by objects or geological structures or by detecting devices using induction coils using several coupled or uncoupled coils
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/041—Printed circuit coils
Abstract
The invention discloses a device for detecting metal particles in working solution, which comprises a signal processing module, a first exciting coil, a second exciting coil and an intermediate feedback coil, wherein the first exciting coil, the second exciting coil and the intermediate feedback coil are arranged at a working solution pipeline. Wherein the first excitation coil generates a first magnetic field, the second excitation coil generates a second magnetic field, and the direction of the magnetic field of the second magnetic field at a neutral point between the first excitation coil and the second excitation coil is opposite to the direction of the magnetic field of the first magnetic field, the intermediate feedback coil is arranged at the neutral point, and the superposed magnetic field of the first magnetic field and the second magnetic field is induced to generate an induction signal; and the signal processing module generates an output signal indicating whether metal particles exist and the size of the metal particles according to the amplitude of the induction signal of the middle feedback coil.
Description
Technical Field
The invention relates to a metal particle detection technology, in particular to a device for detecting metal particles in working solution and a coil manufacturing method thereof.
Background
For products with worn metal parts such as gears, the performance of the products can be effectively ensured by detecting the wear condition of the gears in real time. When the product is lubricated or cooled by oil, metal particle detection equipment can be arranged in a liquid path, specifically, a feedback coil and a symmetrical exciting coil are arranged on a liquid path pipeline, wherein when metal particles pass through the exciting coil and the feedback coil, a magnetic field between the exciting coil and the feedback coil is changed, so that the change of induced voltage on the feedback coil is caused, and therefore whether the metal particles pass through or not can be judged according to the change of the induced voltage of the feedback coil, and further whether component abrasion is generated or not can be judged.
However, in practice, due to dimensional errors of the bobbin, such as the outer diameter, the spacing between the coils, and the like, and coil winding errors, it is physically impossible to make the exciting coil completely symmetrical with respect to the feedback coil, which makes the induced voltage of the feedback coil not 0 when no metal particles pass through. Using a coil that is not perfectly symmetrical can cause the feedback coil to induce a "background voltage"/"noise floor". The amplitude of the voltage change induced in the intermediate feedback coil is small, since metal particles, especially minute metal particles, disturb the magnetic field very little. The presence of "background voltage"/"noise floor" makes it more difficult to detect such small voltage variations. Too large a "background noise"/"background noise" will not even detect a valid signal.
To address this problem, "background voltage"/"noise floor" can be reduced by adding a compensation measure to the outside of the coil, or using a highly accurately machined bobbin, or the like, however the above approach increases production costs.
Disclosure of Invention
In view of some or all of the problems of the prior art, the present invention provides, in one aspect, a working fluid metal particle detection apparatus, including:
a first excitation coil arranged at the working fluid conduit for generating a first magnetic field;
a second excitation coil arranged at the working fluid conduit for generating a second magnetic field, wherein a magnetic field direction of the second magnetic field at a neutral point between the first excitation coil and the second excitation coil is opposite to a magnetic field direction of the first magnetic field;
the middle feedback coil is arranged at the neutral point and used for inducing a superposed magnetic field of the first magnetic field and the second magnetic field to generate an induction signal; and
and the signal processing module is used for generating an output signal which represents whether metal particles exist or not and the size of the metal particles according to the amplitude of the induction signal of the intermediate feedback coil.
Further, the working fluid comprises oil fluid and/or cooling fluid and/or insulating fluid.
Further, the coil windings of the first and/or second excitation coil and/or the intermediate feedback coil are configured such that an amplitude of an induction signal induced by the intermediate feedback coil when no metal particles pass is below a threshold value.
Further, the apparatus further comprises an excitation module electrically connected to the first excitation coil and the second excitation coil, wherein the excitation module is configured to emit an excitation signal such that the first excitation coil and the second excitation coil generate magnetic fields with opposite directions.
Further, a first resonance capacitor is connected between both ends of the intermediate feedback coil and a second resonance capacitor is connected between both ends of the first excitation coil and between both ends of the second excitation coil, and the neutral point is located centrally between the first and second excitation coils.
Further, the equipment further comprises a bobbin arranged on the surface of the working liquid pipeline, the bobbin comprises a first groove, a second groove and a third groove, and the middle feedback coil, the first exciting coil and the second exciting coil are respectively arranged in the second groove, the first groove and the third groove.
Furthermore, a printed circuit board is arranged on one side of the bobbin, the first resonant capacitor and the second resonant capacitor are integrated on the printed circuit board, and the printed circuit board further comprises a connection pad for connecting the intermediate feedback coil, the first exciting coil, the second exciting coil, the exciting module and the signal processing module.
The invention also provides a manufacturing method of the coil in the working solution metal particle detection equipment, which comprises the following steps:
winding a middle feedback coil, a first exciting coil and a second exciting coil on a bobbin, wherein the first exciting coil and the second exciting coil are symmetrically arranged on two sides of the middle feedback coil; and
measuring the amplitude of the induction signal of the intermediate feedback coil when no metal particles pass, and if the amplitude exceeds a threshold value, adjusting the coil arrangement of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil so that the amplitude is lower than the threshold value.
Further, adjusting the coil arrangement of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil comprises the steps of:
adjusting a coil position of an outermost layer of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil such that the amplitude is below the threshold.
According to the working liquid metal particle detection device, the excitation module sends out the excitation signal, so that the first excitation coil and the second excitation coil on the two sides generate magnetic fields in opposite directions, when metal particles pass through the coils from one end, the magnetic fields can change, voltage can be induced in the middle feedback coil, after the induced voltage signal is amplified and processed through the signal processing module, interference or metal particles can be judged, and whether component abrasion occurs or not can be confirmed. In an ideal situation, because the magnetic fields of the first excitation coil and the second excitation coil are the same in size and opposite in direction, no induced voltage is generated in the intermediate coil when no metal particles pass through, and therefore zero setting is required if induced voltage exists.
Drawings
To further clarify the above and other advantages and features of embodiments of the present invention, a more particular description of embodiments of the present invention will be rendered by reference to the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. In the drawings, the same or corresponding parts will be denoted by the same or similar reference numerals for clarity.
FIG. 1 is a schematic diagram of a device for detecting metal particles in a working fluid according to an embodiment of the present invention;
FIG. 2 is a schematic flow chart illustrating a method for manufacturing a coil of an apparatus for detecting metal particles in a working fluid according to an embodiment of the present invention;
FIGS. 3a-3c are schematic diagrams illustrating a process of a coil manufacturing method of a device for detecting metal particles in a working fluid according to an embodiment of the present invention;
FIG. 4 is a schematic circuit diagram of a signal processing device of an apparatus for detecting metal particles in a working fluid according to an embodiment of the present invention; and
fig. 5 is a schematic structural diagram illustrating a calibration system of a device for detecting metal particles in a working fluid according to an embodiment of the present invention.
Detailed Description
In the following description, the present invention is described with reference to various embodiments. One skilled in the relevant art will recognize, however, that the embodiments may be practiced without one or more of the specific details, or with other alternative and/or additional methods, materials, or components. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. Similarly, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the embodiments of the invention. However, the invention is not limited to these specific details. Further, it should be understood that the embodiments shown in the figures are illustrative representations and are not necessarily drawn to scale.
Reference in the specification to "one embodiment" or "the embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase "in one embodiment" in various places in the specification are not necessarily all referring to the same embodiment.
It should be noted that the embodiment of the present invention describes the process steps in a specific order, however, this is only for the purpose of illustrating the specific embodiment, and does not limit the sequence of the steps. Rather, in various embodiments of the present invention, the order of the steps may be adjusted according to process adjustments.
In order to realize the detection of the abrasion of the gear, aiming at the product lubricated or cooled by oil, the invention provides a detection device for metal particles in working fluid, wherein the working fluid refers to oil, cooling fluid, insulating fluid and the like. The scheme of the invention is further described by combining the embodiment drawings.
Fig. 1 is a schematic structural diagram of a device for detecting metal particles in a working fluid according to an embodiment of the present invention. As shown in FIG. 1, the device for detecting metal particles in working fluid comprises a coil, an excitation module 102 and a signal processing module 103.
The coils are wound on a bobbin outside the working fluid pipe 001, and include a first excitation coil 111, a second excitation coil 112, and an intermediate feedback coil 113, which are fixed by an insulating varnish, wherein the coil windings of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil are configured such that an amplitude of an induction signal induced by the intermediate feedback coil when no metal particles pass is lower than a threshold value. The first excitation coil 111 and the second excitation coil 112 are disposed at the working fluid pipeline for generating a first magnetic field and a second magnetic field, in an embodiment of the present invention, the first excitation coil 111 and the second excitation coil 112 are electrically connected to the excitation module 102, the excitation module 102 sends out an excitation signal, so that the first excitation coil generates a first magnetic field and the second excitation coil generates a second magnetic field, wherein a magnetic field direction of the second magnetic field at a neutral point between the first excitation coil and the second excitation coil is opposite to a magnetic field direction of the first magnetic field, the neutral point is centrally located between the first excitation coil and the second excitation coil, and in an embodiment of the present invention, the intermediate feedback coil 113 is disposed at the neutral point for inducing a superimposed magnetic field of the first magnetic field and the second magnetic field to induce a sensing signal. In the embodiment of the present invention, a second resonant capacitor 022 is connected between both ends of the first driving coil 111 and between both ends of the second driving coil 112, and a first resonant capacitor 021 is connected between both ends of the intermediate feedback coil 113.
In one embodiment of the present invention, a bobbin is disposed outside the working fluid pipe 001, the bobbin includes a first groove, a second groove and a third groove, and the middle feedback coil, the first excitation coil and the second excitation coil are disposed in the second groove, the first groove and the third groove, respectively.
The signal processing module 103 is electrically connected to the intermediate feedback coil 113, and is configured to sense a voltage of the intermediate feedback coil, amplify the voltage, and generate an output signal indicating whether metal particles exist and sizes of the metal particles according to an amplitude of a sensing signal of the intermediate feedback coil. In an embodiment of the present invention, a printed circuit board is further disposed on one side of the bobbin, the first resonant capacitor 021 and the second resonant capacitor 022 are integrated on the printed circuit board, and the printed circuit board further includes a connection pad for connecting the intermediate feedback coil, the first excitation coil, the second excitation coil, the excitation module and the signal processing module.
The coil is limited by the manufacturing process, and the coil is difficult to be completely symmetrical in physical structure, so that the induction voltage in the middle feedback coil is not 0 even if no metal particles pass through the coil, the difficulty of detecting a tiny induction signal is further increased, and the voltage is called as background voltage or background noise. In order to eliminate the background voltage, the invention optimizes the coil manufacturing method of the working solution metal particle detection equipment. Fig. 2 and 3a-3c respectively show a flow chart and a process diagram of a coil manufacturing method of a working fluid metal particle detection device according to an embodiment of the invention. As shown in the figure, the method for manufacturing the coil in the oil working fluid metal particle detection device comprises the following steps:
first, in step 201, an initial coil is wound. Winding a middle feedback coil 113, a first excitation coil 111 and a second excitation coil 112 on a bobbin 002, wherein the first excitation coil and the second excitation coil are symmetrically arranged at two sides of the middle feedback coil, the state of the coil after primary winding is shown in fig. 3a, the bobbin 002 is wrapped on the outer surface of the working fluid pipeline 001, the bobbin 002 comprises a first groove 0021, a second groove 0022 and a third groove 0023, the first groove and the third groove are symmetrically arranged at two sides of the second groove, the first excitation coil 111 is wound in the first groove, the middle feedback coil is wound in the second groove, the second excitation coil is wound in the third groove, a first resonant capacitor 021 and a second resonant capacitor 022 are integrated on a printed circuit board 003, and the printed circuit board 003 is electrically connected with the first excitation coil 111 and the second excitation coil 112 through a first bonding pad 031 and is electrically connected with the middle feedback coil 113 through a second bonding pad 032;
next, at step 202, the coil arrangement is adjusted. Measuring the amplitude of the induction signal of said intermediate feedback coil when no metal particles pass, and if said amplitude exceeds a threshold value, adjusting the coil arrangement of the first excitation coil and/or the second excitation coil and/or said intermediate feedback coil such that said amplitude is below said threshold value, in one embodiment of the invention the adjustment of the coil arrangement comprises: adjusting a coil position of an outermost layer of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil such that the amplitude is below the threshold. In the embodiment of fig. 3b, this is achieved by adjusting the outermost coil position of the intermediate feedback coil: firstly, according to the difference value between the amplitude value and the threshold value, adjusting 72-74 turns of the outermost winding to be close to one side of the first excitation coil, measuring the amplitude value of the induction signal of the middle feedback coil again, and if the amplitude value is still higher than the threshold value, further adjusting 68-74 turns of the outermost winding to be close to one side of the first excitation coil, as shown in fig. 3c, and at the moment, the amplitude value is lower than the threshold value, and finishing the coil arrangement; and
finally, in step 203, the coil is secured. The fixing is performed by using insulating varnish 004 to prevent the coil winding position from changing.
Since the signal induced by the microparticles is small, high magnification is usually required to detect the signal. When the large-size metal particles pass through the coil, the feedback coil induces a large-amplitude induction signal, and the signal after high-power amplification is saturated, so that the large-size particles cannot be identified. To solve this problem, in an embodiment of the present invention, the signal processing module 103 includes a signal processing device for detecting metal particles in the working fluid, wherein multiple amplification and analog-to-digital conversion circuits are provided, and the amplification factor of each of the multiple amplification circuits is different, and all the signals are transmitted to an induction signal processing device, such as a micro central processing unit (MCU), for comprehensive judgment, and the output signal of the amplification circuit with the smallest amplification factor does not reach saturation (i.e., does not reach the induction signal of the metal particles with the largest size), so as to detect not only micro particles but also large metal particles, thereby expanding the detection range. Fig. 4 is a schematic circuit diagram of a signal processing device of an operating fluid metal particle detection apparatus according to an embodiment of the present invention. As shown in fig. 4, the signal processing module 103 includes a primary filtering and amplifying circuit 301, a plurality of secondary amplifying circuits 3021, 3022 … … n and analog-to- digital conversion circuits 3031, 3032 … … n, and an inductive signal processing device 304. The input end of the primary filtering and amplifying circuit 301 is connected to two ends of the intermediate feedback coil, and is configured to perform primary filtering and amplifying on the induction signal, and the output end of the primary filtering and amplifying circuit 301 is connected to the input ends of the secondary amplifying circuits 3021, 3022 … … n, where the primary filtering and amplifying circuit 301 includes a filtering circuit and a primary amplifying circuit; the input ends of the analog-to- digital conversion circuits 3031 and 3032 … … n are respectively connected to the output ends of the two- stage amplification circuits 3021 and 3022 … … n for performing analog-to-digital conversion on analog signals output by the two-stage amplification circuits, and the sensing signal processing device 304 is connected to the output ends of the analog-to- digital conversion circuits 3031 and 3032 … … n for judging whether metal particles exist or not according to the output values of the analog-to-digital conversion circuits and determining the sizes of the metal particles. In the embodiment of the present invention, the amplification factor of each secondary amplification circuit is set according to the size of the metal particles that can be generated, and the larger the metal particles that can be generated, the smaller the amplification factor setting of the secondary amplification circuit. In one embodiment of the invention, two-stage amplification circuits are provided, including a first amplification circuit and a second amplification circuit, wherein the first amplification circuit is used for amplifying the induction signal by a first amplification factor, wherein the first amplification factor is set to a size that enables the induction signal processing device to determine the existence of the metal particles with a first size by analyzing the induction signal amplified by the first amplification factor; and a second amplifying circuit for amplifying the sensing signal by a second amplification factor, wherein the second amplification factor is set such that the amplitude of the sensing signal amplified by the second amplification factor does not reach saturation, i.e. the sensing signal processing apparatus can determine the presence of metal particles having a second size by analyzing the sensing signal amplified by the second amplification factor, wherein the second size is larger than the first size, and the second size is the size of the metal particles that are most likely to occur in the working fluid.
Based on the signal processing device, the detection and size judgment of the metal particles comprises the following steps:
when metal particles pass through the coils, the intermediate feedback coils generate induction signals, the induction signals are filtered and primarily amplified by the primary filtering and amplifying circuit, then are output to each amplifier to be amplified by different times, finally, the amplified signals are subjected to analog-to-digital conversion and then are transmitted to the induction signal processing device, and the induction signal processing device calculates the amplitude of the induction signals generated by the intermediate feedback coils according to the output values of each analog-to-digital conversion circuit, so that whether the metal particles exist or not and the size of the metal particles are determined. In one embodiment of the present invention, the sensing signal processing device may also send an alarm to remind a component replacement or repair should a particle exceed a threshold size occur.
In this application, the term "signal does not reach saturation" means that the signal does not reach the maximum range or the upper limit of the detection range of the detection or analysis instrument or the sensing signal processing device, i.e. the signal does not reach the sensing signal corresponding to the maximum particle size that may occur. That is, after signal amplification, the detection or analysis instrument or the inductive signal processing device can still determine the correct result, here the metal particle size, from the amplified signal without causing signal saturation or overflow.
In yet another embodiment of the present invention, a conversion relation table between the signal amplitude and the particle size is stored in the processor, and after the processor acquires the output value of each analog-to-digital conversion circuit, the particle size can be accurately determined according to the conversion relation table. Wherein the conversion relation table is obtained through factory calibration. Fig. 5 is a schematic structural diagram illustrating a calibration system of a device for detecting metal particles in a working fluid according to an embodiment of the present invention. As shown in fig. 5, the calibration system includes a control center 402, a particle emitting device 404, and a plurality of air pipes 403. The plurality of air pipes 403 are arranged inside the working fluid pipeline 001 and penetrate through a detection area of the working fluid metal particle detection device, one end of each air pipe is connected with the particle emitting device 404 and used for containing metal particles emitted by the particle emitting device, the particle emitting device 404 can emit metal particles with different sizes in the air pipe under the control of the control center 402 to simulate the state that the metal particles flow through the working fluid pipeline in practical application, the control center 402 is connected with the signal processing module 103 in a communication mode through a power supply and a communication connection line 401 and used for controlling the particle emitting device and sending particle size data to the signal detection module, and then the working fluid metal particle detection device is calibrated according to the size of the emitted metal particles and induction signals corresponding to the metal particles received from the working fluid metal particle detection device. The process of calibrating the working fluid metal particle detection equipment comprises the following steps:
firstly, a control center controls a particle emitting device to continuously and repeatedly send metal particles with the same size, meanwhile, size information of the metal particles is transmitted to a signal detection module, and after the emitted metal particles reach a trachea stopping position, the metal particles can freely fall to the trachea starting position;
next, the signal detection module stores the detected induction signal amplitude and the corresponding particle size;
then, the control center controls the particle emitting device to switch an emitting air pipe, emits metal particles with the size value increased by one, and repeats the steps until the emitting of the metal particles with the maximum size is finished; and
and finally, the signal detection module fits a 'signal amplitude and particle size conversion relation table' according to all the induction signal amplitudes and the corresponding particle sizes, and stores the conversion relation table in an internal memory.
In one embodiment of the present invention, the calibrating and detecting the size of the metal particles comprises calibrating only the smallest and largest possible sizes of the metal particles, and recording the smallest possible size as the first size and the largest possible size as the second size:
storing a first size of metal particles and a first sensing signal corresponding to the metal particles received from a working fluid metal particle detection device;
storing a second size of the metal particles and a second sensing signal corresponding to the metal particles received from the working fluid metal particle detection device, wherein the second size is larger than the first size; and
when the working fluid metal particle detection apparatus detects a third induced signal corresponding to metal particles of a third size between the first and second sizes, the third size is determined by signal fitting the first and second sizes and the first and second induced signals.
According to the working solution metal particle detection equipment provided by the invention, firstly, the coil symmetry is improved by a method of adjusting the coil, and the production cost is reduced; secondly, a multi-path amplifying and analog-to-digital conversion circuit is used in the signal processing module, so that the detection range of the particles is enlarged; and finally, calibrating the detection signal when the monitoring device leaves the factory, so that the detection device can directly output the particle size information and clearly indicate the working state of the monitored device.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various combinations, modifications, and changes can be made thereto without departing from the spirit and scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
Claims (9)
1. An operating fluid metal particle detection apparatus, comprising:
a first excitation coil arranged at the working fluid conduit and configured to be capable of generating a first magnetic field;
a second excitation coil disposed at the working fluid conduit and configured to be capable of generating a second magnetic field, wherein a magnetic field direction of the second magnetic field at a neutral point between the first excitation coil and the second excitation coil is opposite to a magnetic field direction of the first magnetic field;
an intermediate feedback coil disposed at the neutral point and configured to be capable of inducing a superimposed magnetic field of the first magnetic field and the second magnetic field to inductively generate an induced signal; and
a signal processing module configured to be able to generate an output signal representing the presence and size of metal particles from the amplitude of the inductive signal of the intermediate feedback coil, the signal processing module comprising:
the input end of the primary filtering and amplifying circuit is connected with two ends of the middle feedback coil, the output end of the primary filtering and amplifying circuit is connected to the input end of each secondary amplifying circuit, and the primary filtering and amplifying circuit comprises a filtering circuit and a primary amplifying circuit;
a plurality of secondary amplification circuits, wherein each secondary amplification circuit has a different specified amplification factor, the specified amplification factor being sized such that the sensing signal processing means can determine the presence of metal particles having a corresponding size by analyzing the sensing signal amplified by the specified amplification factor;
a plurality of analog-to-digital conversion circuits, the input ends of which are respectively connected to the output ends of the secondary amplification circuits, and which are configured to perform analog-to-digital conversion on the analog signals output by the secondary amplification circuits; and
and the induction signal processing device is connected with the output end of the analog-to-digital conversion circuit and is configured to judge whether metal particles exist or not according to the output value of each analog-to-digital conversion circuit and determine the size of the metal particles.
2. The apparatus of claim 1, wherein the working fluid comprises oil and/or cooling fluid and/or insulating fluid.
3. The apparatus for detecting metal particles in an operating fluid according to claim 1, wherein the coil windings of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil are configured such that an amplitude of an induction signal induced by the intermediate feedback coil when no metal particles pass is lower than a threshold value.
4. The apparatus of claim 1, further comprising an excitation module electrically coupled to the first and second excitation coils, the excitation module configured to emit an excitation signal such that the first and second excitation coils generate magnetic fields in opposite directions.
5. The apparatus of claim 1, wherein a first resonant capacitor is connected between the ends of the intermediate feedback coil and a second resonant capacitor is connected between the ends of the first drive coil and the ends of the second drive coil, and the neutral point is centrally located between the first and second drive coils.
6. The apparatus of claim 1, further comprising a bobbin disposed between the working fluid conduit and the coil, the bobbin comprising a first recess, a second recess, and a third recess, the intermediate feedback coil, the first excitation coil, and the second excitation coil being disposed in the second recess, the first recess, and the third recess, respectively.
7. The apparatus of claim 6, wherein a printed circuit board is disposed at one side of the bobbin and electrically connected to the first exciting coil, the second exciting coil, the intermediate feedback coil, the exciting module and the signal processing module.
8. A method for manufacturing a coil in an apparatus for detecting metal particles in a working fluid according to any one of claims 1 to 7, comprising the steps of:
winding a middle feedback coil, a first exciting coil and a second exciting coil on a bobbin, wherein the first exciting coil and the second exciting coil are symmetrically arranged on two sides of the middle feedback coil; and
and measuring the amplitude of the induction signal of the intermediate feedback coil, and if the amplitude exceeds a threshold value, adjusting the position of the outermost coil of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil so that the amplitude is lower than the threshold value.
9. The manufacturing method according to claim 8, wherein the coil position of the outermost layer of the first excitation coil and/or the second excitation coil and/or the intermediate feedback coil is determined based on a difference between the amplitude and a threshold value.
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| US5793199A (en) * | 1995-11-10 | 1998-08-11 | New Cosmos Electric Co., Ltd. | Method and apparatus for determining magnetic powder concentration by using the electromagnetic induction method |
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| CN107340544A (en) * | 2016-11-29 | 2017-11-10 | 北京理工大学 | A kind of highly sensitive minute metallic particle on-line detecting system and method |
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