CN113984600A - High-sensitivity metal wear particle online detection sensor based on magnetostatic iron - Google Patents
High-sensitivity metal wear particle online detection sensor based on magnetostatic iron Download PDFInfo
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- CN113984600A CN113984600A CN202111256032.4A CN202111256032A CN113984600A CN 113984600 A CN113984600 A CN 113984600A CN 202111256032 A CN202111256032 A CN 202111256032A CN 113984600 A CN113984600 A CN 113984600A
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Abstract
The invention discloses a high-sensitivity metal wear particle on-line detection sensor based on magnetostatic iron, which comprises a sensor shell, a non-magnetic-conductive material gasket, an inner fixed seat, a first coil substrate, a first oil pipe channel, a second coil substrate, an upper strong magnetostatic iron, a lower strong magnetostatic iron, a first induction coil and a second induction coil, wherein two upper strong magnetostatic iron and lower strong magnetostatic iron poles with completely the same parameters are oppositely arranged, a gap is formed between the two magnets at a certain distance, the induction coil is arranged at the right middle position of the gap, namely the inner side or the outer side of a circular ring of the two circular magnets, so that the central axis of the induction coil is parallel to the central axis of the circular magnets, the effective detection of the sensor on metal wear particles is realized, and the coupling distance between the sensors is changed by adjusting the outer diameter, the thickness and the gap distance of the circular magnets, the effect of enhancing the sensitivity of the sensor is achieved.
Description
Technical Field
The invention relates to a detection sensor, in particular to a high-sensitivity metal wear particle online detection sensor based on magnetostatic iron, and belongs to the technical field of metal wear particle online detection.
Background
When the mechanical equipment is in operation, the moving webs generate mutual friction and abrasion phenomena, so that a large amount of metal abrasion particles are generated. These wear particles further increase the wear phenomena as the lubricant runs through the mechanical equipment, and the metal wear particles, which are the products of the wear phenomena, contain a large amount of information about the wear status of the mechanical equipment. Relevant studies show that the more 70% of mechanical failures are caused by abnormal wear, the monitoring of the wear state of mechanical equipment can effectively help to evaluate the health state of the equipment and avoid serious mechanical failures. Therefore, the method has great significance for real-time online monitoring of wear particle information in the lubricating oil and early fault diagnosis and prediction of mechanical equipment.
A great deal of research work has been done on metal wear particles in lubricating oil at home and abroad, and there have been significant achievements. At present, offline abrasion detection technologies such as an iron spectrum analyzer, a spectrum analyzer and a particle counter are widely applied due to the characteristics of high sensitivity and high monitoring precision, but generally have high cost, low efficiency and complex structure. However, as the complexity and reliability requirements for large equipment increase, there is an increasing demand for online wear monitoring, particularly in the military field and in the air transportation industry. Because the friction contact surface can generate a large amount of wear particles in the wear process, the particles which are the products of the wear phenomenon often contain abundant mechanical wear state information, and therefore, the wear state of mechanical equipment can be reflected by carrying out online monitoring and analysis on the characteristic parameters of the wear particles in the lubricating oil. Furthermore, the material and shape of the wear particles can respectively represent the wear position and wear mechanism of the machine to a certain extent, and the size and quantitative distribution of the wear particles can directly reflect the wear degree of the machine. Therefore, in order to continuously monitor the wear state of the machine and avoid serious mechanical failures, a lot of research is carried out on the basis of on-line wear particle monitoring sensors. However, most of domestic research is still in the laboratory stage so far, the standard of engineering application is not achieved, and the defects of high cost and complex manufacturing process exist in few sensors which can achieve the standard of engineering application. Therefore, it is an urgent problem to research an online metal wear particle monitoring sensor with simple manufacturing process and low cost.
Disclosure of Invention
The invention aims to provide a high-sensitivity metal wear particle online detection sensor based on static magnet, so as to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme: a high-sensitivity metal wear particle online detection sensor based on magnetostatic iron comprises a sensor shell, a non-magnetic material-permeable gasket, an inner fixed seat, a first coil base body, a first oil pipe channel, a second coil base body, an upper strong magnetostatic iron, a lower strong magnetostatic iron, a first induction coil and a second induction coil, wherein the sensor shell is fixedly connected with the inner fixed seat, the inner fixed seat is internally provided with the upper strong magnetostatic iron and the strong magnetostatic iron, the upper strong magnetostatic iron and the strong magnetostatic iron are connected with the non-magnetic material gasket, the sensor shell is respectively connected with the first oil pipe channel and the second oil pipe channel in a penetrating mode, the middle of the first oil pipe channel is connected with the first coil base body, the first coil base body is connected with the first induction coil base body, and the second oil pipe channel is connected with the second coil base body, the interior of the second coil substrate is connected with a second induction coil.
As a preferable technical scheme of the invention, the first induction coil and the second induction coil are wound by using a covered wire with the diameter of 0.1mm, and the number of turns of the first induction coil and the number of turns of the second induction coil are both 1000 turns.
As a preferable technical scheme of the invention, the uniform strong static magnet and the strong static magnet are made of neodymium iron boron materials.
As a preferable technical solution of the present invention, the first coil base body and the second coil base body are both made of a non-magnetic conductive material.
As a preferred technical scheme of the present invention, the first oil pipe channel and the second oil pipe channel are both made of a non-magnetic material, the first oil pipe channel and the first coil base body are in transition fit connection, and the second oil pipe channel and the second coil base body are in transition fit connection.
As a preferable technical scheme of the invention, a magnetic shielding layer and an electric shielding layer are sequentially arranged on the inner wall of the sensor shell.
As a preferred technical solution of the present invention, the first coil base, the first induction coil, and the first oil pipe passage may be distributed along a circumferential direction of an inner diameter of the magnet, and the maximum distribution number is related to a spatial dimension.
As a preferred technical solution of the present invention, the second coil substrate, the second induction coil, and the second oil pipe passage may be distributed along a circumferential direction of an outer diameter of the magnet, and a maximum distribution number is related to a spatial dimension.
Compared with the prior art, the invention has the beneficial effects that:
1. the invention relates to a high-sensitivity metal wear particle on-line detection sensor based on magnetostatic iron, which is characterized in that two upper strong magnetostatic iron poles and lower strong magnetostatic iron poles with the same parameters are oppositely arranged, a gap is formed between the two magnets at a certain distance, an induction coil is arranged at the middle position of the gap, namely the inner side or the outer side of a circular ring of the two circular magnets, so that the central axis of the induction coil is parallel to the central axis of the circular magnets, the metal wear particles are effectively detected by the sensor, and meanwhile, the coupling distance between the sensors is changed by adjusting the outer diameter, the thickness and the gap distance of the circular magnets, and the sensitivity of the sensor is enhanced.
Drawings
FIG. 1 is a schematic view of the overall structure of the present invention;
FIG. 2 is a schematic diagram of the sensor module of the present invention;
FIG. 3 is a simulated cloud of magnetic field strength generated by the coaxial and opposite magnetic pole arrangement of two ring magnets of the present invention;
FIG. 4 is a graph of the magnetic flux density at the middle X-axis of the two magnet gaps of the present invention;
FIG. 5 is a graph of the induced voltage of the induction coil of the present invention inside and outside the ring magnet in comparison;
FIG. 6 is a schematic diagram of the effect of different thickness ring magnets on induced electromotive force of the present invention;
FIG. 7 is a schematic diagram of the effect of different outer radius ring magnets of the present invention on induced electromotive force;
FIG. 8 is a schematic diagram of the effect of different gap distances between two ring magnets on the induced electromotive force of the present invention;
figure 9 is a schematic illustration of the expandable position and number of induction coils and oil conduits of the present invention.
In the figure: 1. a sensor housing; 2. a non-magnetically permeable material spacer; 3. an inner fixed seat; 4. a coil base; 5. a first tubing passage; 6. a second tubing passage; 7. a coil base; 8. an upper strong magnetostatic iron; 9. a lower strong magnetostatic iron; 10. a first induction coil; 11. a second induction coil.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-9, the present invention provides a technical solution of a high-sensitivity metal wear particle on-line detection sensor based on magnetostatic iron:
as shown in fig. 1, the invention provides a high-sensitivity metal wear particle online detection sensor based on magnetostatic iron, which comprises a sensor shell 1, a non-magnetic material-conductive gasket 2, an inner fixed seat 3, a first coil substrate 4, a first oil pipe channel 5, a second oil pipe channel 6, a second coil substrate 7, a first strong magnetostatic iron 8, a second strong magnetostatic iron 9, a first induction coil 10 and a second induction coil 11, wherein during operation, the two strong magnetostatic irons are separated by the non-magnetic material-conductive gasket 2 and fixed in the sensor shell 1, the coil substrate 4, the oil pipe channel 5 and the induction coil 10 jointly form a sensor detection group, and the coil substrate 7, the oil pipe channel 6 and the induction coil 11 jointly form another sensor detection group; when the sensor works, only one sensor detection group is arranged, lubricating oil with metal wear particles flows through the first oil pipe passage 5 or the second oil pipe passage 6 and passes through magnetic fields with opposite directions provided by the first strong static magnet 8 and the second strong static magnet 9, and the first induction coil 10 and the second induction coil 11 are used for detecting magnetic field disturbance caused when the lubricating oil with metal wear particles flows through the oil pipe passages.
In the above example, as shown in fig. 2, the method includes: the oil pipe comprises a first strong static magnet 8, a second strong static magnet 9, a first induction coil 10 and a second induction coil 11, wherein the first strong static magnet 8 and the second strong static magnet 9 are coaxially arranged, the magnetic poles of the first strong static magnet 8 and the second strong static magnet 9 are opposite and are arranged at a certain distance, the first induction coil 10 and the second induction coil 11 are respectively arranged at the inner side or the outer side of the gap between the first strong static magnet 8 and the second strong static magnet 9, and a first oil pipe channel 5 and a second oil pipe channel 6 are respectively arranged at the inner side of the first induction coil 10 and the second induction coil 11 and are coaxially distributed.
In a preferred embodiment, in order to study the influence of the induction coil being arranged inside and outside the ring magnet on the detection sensitivity of the sensor, the results of the analysis of the induction coil being arranged inside the ring magnet and the induction coil being arranged outside the ring magnet, respectively, indicate that the induction coil is most effective when arranged outside the ring magnet.
In a preferred embodiment, in order to study the influence of the thickness of the ring magnet on the detection sensitivity of the sensor, the sensors with the thicknesses of the ring magnets of 2mm, 5mm and 10mm are respectively analyzed, and the results show that the induced voltage of the induction coil is increased along with the increase of the thickness of the ring magnet, namely the detection sensitivity of the sensor is increased along with the increase of the thickness of the ring magnet.
In a preferred embodiment, in order to study the influence of the cross-sectional width of the ring magnet on the detection sensitivity of the sensor, the sensors with outer radii of the ring magnet of 15mm, 20mm and 25mm were analyzed, respectively, and the results showed that as the outer radius of the ring magnet increased, the induced voltage of the induction coil increased, that is, the detection sensitivity of the sensor increased as the outer radius of the ring magnet increased.
In a preferred embodiment, in order to study the influence of the gap distance between the two ring magnets on the detection sensitivity of the sensor, the sensors with the gap distances between the two ring magnets of 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm and 7mm are respectively studied and analyzed, and the result shows that when the gap distance between the two ring magnets is 5mm, the induction voltage of the induction coil is the largest, and the sensitivity of the sensor is the strongest.
In the above embodiments, as shown in fig. 2, the sensor module includes two annular static magnets with identical geometric parameters, which are coaxially arranged, and the magnetic poles of the two magnets are oppositely arranged, and a gap with a certain distance is left between the two magnets, so that the two magnets form a place with the maximum magnetic field strength on the cross section of the gap between the two magnets, thereby increasing the total magnetic energy change caused by the wear particles passing through the magnetic field, and increasing the induced electromotive force of the induction coil. Firstly, determining the influence of the position of the induction coil on the induced electromotive force by arranging the induction coil at different positions on the inner side and the outer side of the annular magnet; then, the influence rule of different magnet parameters on the induced electromotive force is found by changing the thickness and the outer radius of the two annular magnets; and finally, determining the optimal distance of the induced electromotive force of the gap enhanced induction coil of the two magnets by adjusting different gap distances between the two magnets.
As shown in fig. 3, the simulated cloud of the magnetic field generated by the coaxial magnetic poles of the two ring magnets are arranged oppositely, and the magnetic field intensity reaches the maximum respectively at the inner side and the outer side of the gap between the two ring magnets.
The flux density plot at the axis of the X-axis, between the two magnet gaps, as shown in fig. 4, shows that the flux density peaks inside and outside the ring magnets, respectively, further validating the results shown in fig. 3.
As shown in fig. 5, as can be seen from a comparison of the induced voltages of the induction coil inside and outside the ring magnet, the induced voltage when the induction coil is disposed outside the ring magnet is larger than the induced voltage when the induction coil is disposed inside the ring magnet, i.e., the sensitivity when the induction coil is disposed outside the ring magnet is higher.
As shown in fig. 6, when the coil is arranged outside the ring magnet, the influence of the ring magnets with the same inner radius and outer radius and different thicknesses on the induced electromotive force is shown, and the induced voltage of the coil is increased when the thickness of the magnet is increased.
As shown in fig. 7, when the coil is disposed outside the ring magnet, the influence of the ring magnets with the same thickness and inner radius and different outer radii on the induced electromotive force is schematically shown, and the induced voltage of the coil tends to increase as the outer radius of the magnet increases.
As shown in fig. 8, when the coil is arranged outside the ring magnet, the induced electromotive force influence when the coil is arranged outside the ring magnet and the gap distance between the two magnets is different is shown schematically, and a first-rising and second-falling arc curve is shown. The result shows that when the gap between the two magnets is 5mm, the induction voltage is maximum, and the detection effect of the sensor is best.
As shown in fig. 9, the number and positions of the induction coils, the coil base and the oil passages can be changed according to needs, for example, the number of the inner induction coils, the coil base and the oil passages can be increased to two or more than two at the same time; the inner side induction coil, the outer side induction coil, the coil base body and the oil pipeline can be arranged at the same time; the number of the outer induction coils, the coil base body and the oil through pipe can be increased to two or more; the arrangement angles of the induction coil, the coil base body and the oil through pipe can be flexibly adjusted according to the requirement. The detection efficiency of the metal wear particles can be greatly improved by increasing the number of the induction coils, the coil base body and the oil through pipe.
When the sensor module is used, the second strong static magnet 9 generates a vertically downward magnetic field, the first strong static magnet 8 generates a vertically upward magnetic field which is equal to the strong static magnet 1 in size and opposite in direction, the two magnetic fields are mutually offset, when no metal particles pass through the sensor module, the two magnetic fields are mutually offset at the induction coil, the magnetic flux of the induction coil is changed into 0, and no induced electromotive force is output. When metal particles enter the sensor, the metal wear particles cause disturbance of a magnetic field at the induction coil, so that the induction coil generates induced electromotive force, and the induced electromotive force is increased along with the increase of the diameter of the metal wear particles.
Based on the detection system, the theoretical parts of the high-sensitivity metal wear particle online detection sensor based on the static magnet are as follows:
in order to calculate the magnetic induction intensity distribution of ferromagnetic sphere abrasion particles in a static magnetic field, the magnetic field intensity distribution around the abrasion particles can satisfy the following conditions according to a fourth equation of a Maxwell equation system:
in the formula: h is the magnetic field strength, JrCurrent density and D is the electric displacement vector.
When the magnetic induction intensity of the background magnetic field is weaker and the wear particles do not reach magnetic saturation, the magnetic induction intensity distribution inside the wear particles of the ferromagnetic sphere is as follows:
in the formula: r is the distance from the center of the sphere, raRadius of sphere in static magnetic field, permeability of ferromagnetic particles, mu0Magnetic permeability in vacuum, HpIs the total magnetic field strength, B, within the ferromagnetic sphere particles in the static magnetic field0The magnetic induction intensity of the background uniform magnetic field.
Since the magnetic permeability of ferromagnetic particles is much greater than that of vacuum (μ > μ)0) Therefore, in static magnetic field, the magnetic induction intensity inside the ferromagnetic sphere abrasion particles is uniformly distributed and can be similar toEqual to 3 times the background magnetic induction.
Considering the quantitative magnetic potential distribution of ferromagnetic sphere abrasion particles in a static magnetic field and considering the influence of a background magnetic field, the magnetic induction intensity distribution in the air around the abrasion particles is as follows:
in the formula:
the distribution of the magnetic potential of ferromagnetic sphere abrasion particles in a static magnetic field is marked, and M is the magnetization intensity of the ferromagnetic abrasion particles.
When metal wear particles pass through a magnetic field emitted by static magnets, magnetic energy changes of the magnetic field at the positions of the particles can be caused by changes of magnetic induction intensity in the metal particles and in the surrounding air. In a static magnetic field, the energy W of the magnetic field inside the abrasive particlespAnd the resulting local magnetic field magnetic energy change Δ WpAre respectively shown as formulas (2-20) and (2-21), wherein V ispTo wear particle volume, Wp0Is the magnetic energy of the background magnetic field in the air of the same volume as the abrasive particles.
From the above formula, the magnetic energy inside the spherical wear particles in the static magnetic field and the resulting magnetic energy change are proportional to the square of the background magnetic induction and the third power of the radius of the wear particles.
The total magnetic energy Wa in the air surrounding the wear particles is:
the magnetic energy change Δ Wa caused by the wear particles can be expressed as:
at this time, the total magnetic energy change Δ W due to ferromagnetic sphere abrasion particles in the static magnetic fieldmfCan be expressed as:
ΔWmf＝ΔWp+ΔWa
according to the formula, the magnetic energy change caused when the wear particles pass through the magnetic field inside the sensor is related to the background magnetic induction intensity and the radius of the wear particles. When the radius of the abrasion particles is fixed, the geometric parameters of the static magnet and the gap distance between the two magnets are changed, so that the background magnetic induction intensity of the sensor is changed, and the change of the magnetic energy of the abrasion particles passing through the sensor is increased. Formula for calculating induced current in closed circuit by electromagnetic induction phenomenon
It is known that the increase of the magnetic energy variation causes the magnetic flux of the induction coil
Induces an electromotive force E and a magnetic flux
The induced electromotive force is increased along with the proportional relation, so that the detection sensitivity of the sensor can be increased.
In the description of the present invention, it is to be understood that the indicated orientations or positional relationships are based on the orientations or positional relationships shown in the drawings and are only for convenience in describing the present invention and simplifying the description, but are not intended to indicate or imply that the indicated devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and are not to be construed as limiting the present invention.
In the present invention, unless otherwise explicitly specified or limited, for example, it may be fixedly attached, detachably attached, or integrated; can be mechanically or electrically connected; the terms may be directly connected or indirectly connected through an intermediate, and may be communication between two elements or interaction relationship between two elements, unless otherwise specifically limited, and the specific meaning of the terms in the present invention will be understood by those skilled in the art according to specific situations.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (8)
1. A high-sensitivity metal wear particle online detection sensor based on magnetostatic iron comprises a sensor shell (1), a non-magnetic material-permeable gasket (2), an inner fixed seat (3), a first coil base body (4), a first oil pipe channel (5), a second oil pipe channel (6), a second coil base body (7), an upper strong magnetostatic iron (8), a lower strong magnetostatic iron (9), a first induction coil (10) and a second induction coil (11), and is characterized in that the sensor shell (1) is fixedly connected with the inner fixed seat (3), the inner fixed seat (3) is internally provided with the upper strong magnetostatic iron (8) and the strong magnetostatic iron (9), the upper strong magnetostatic iron (8) and the strong magnetostatic iron (9) are connected with the non-magnetic material-permeable gasket (2), the sensor shell (1) is respectively connected with the first oil pipe channel (5) and the second oil pipe channel (6) in a penetrating manner, the middle part of the first oil pipe channel (5) is connected with the first coil base body (4), the inside of the first coil base body (4) is connected with the first induction coil (10), the middle part of the second oil pipe channel (6) is connected with the second coil base body (7), and the inside of the second coil base body (7) is connected with the second induction coil (11).
2. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: first induction coil (10) and second induction coil (11) all adopt the diameter to be 0.1 mm's envelope winding to form, the number of turns of first induction coil (10) and the number of turns of second induction coil (11) are 1000 circles.
3. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the uniform strong static magnet (8) and the strong static magnet (9) are made of neodymium iron boron materials.
4. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the first coil substrate (4) and the second coil substrate (7) are both made of non-magnetic materials.
5. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the first oil pipe channel (5) and the second oil pipe channel (6) are both made of non-magnetic materials, the first oil pipe channel (5) is in transition fit connection with the first coil base body (4), and the second oil pipe channel (6) is in transition fit connection with the second coil base body (7).
6. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the inner wall of the sensor shell (1) is sequentially provided with a magnetic shielding layer and an electric shielding layer.
7. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the first coil base body (4), the first induction coil (10) and the first oil pipe channel (5) can be distributed along the circumferential direction of the inner diameter of the magnet, and the maximum distribution quantity is related to the space size.
8. The static magnet-based high-sensitivity metal wear particle on-line detection sensor according to claim 1, characterized in that: the second coil substrate (7), the second induction coil (11) and the second oil pipe channel (6) can be distributed along the circumferential direction of the outer diameter of the magnet, and the maximum distribution quantity is related to the space size.
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| 张海营: "《承压类特种设备超声检测新技术与应用》", vol. 2020, 黄河水利出版社, pages: 119 - 120 * |
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