CN115372209B - High-sensitivity oil abrasive particle online monitoring system and monitoring method - Google Patents
High-sensitivity oil abrasive particle online monitoring system and monitoring method Download PDFInfo
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- CN115372209B CN115372209B CN202210813088.3A CN202210813088A CN115372209B CN 115372209 B CN115372209 B CN 115372209B CN 202210813088 A CN202210813088 A CN 202210813088A CN 115372209 B CN115372209 B CN 115372209B
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 28
- 239000002245 particle Substances 0.000 title claims abstract description 23
- 238000000034 method Methods 0.000 title claims abstract description 17
- 230000006698 induction Effects 0.000 claims abstract description 83
- 230000005284 excitation Effects 0.000 claims abstract description 56
- 239000002923 metal particle Substances 0.000 claims abstract description 34
- 238000012545 processing Methods 0.000 claims abstract description 21
- 239000000523 sample Substances 0.000 claims abstract description 16
- 238000001914 filtration Methods 0.000 claims abstract description 10
- 239000003990 capacitor Substances 0.000 claims description 22
- 238000006243 chemical reaction Methods 0.000 claims description 11
- 230000003321 amplification Effects 0.000 claims description 6
- 238000003199 nucleic acid amplification method Methods 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N Alumina Chemical compound [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 230000007274 generation of a signal involved in cell-cell signaling Effects 0.000 claims description 2
- 238000001514 detection method Methods 0.000 abstract description 18
- 239000003921 oil Substances 0.000 abstract description 13
- 239000010687 lubricating oil Substances 0.000 abstract description 6
- 239000002184 metal Substances 0.000 abstract description 6
- 230000001050 lubricating effect Effects 0.000 abstract description 3
- 230000005294 ferromagnetic effect Effects 0.000 description 10
- 238000010586 diagram Methods 0.000 description 6
- 230000005291 magnetic effect Effects 0.000 description 6
- 230000000694 effects Effects 0.000 description 2
- 230000001939 inductive effect Effects 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Classifications
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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
- G01N15/0266—Investigating particle size or size distribution with electrical classification
-
- 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
- G01N15/06—Investigating concentration of particle suspensions
- G01N15/0656—Investigating concentration of particle suspensions using electric, e.g. electrostatic methods or magnetic methods
Abstract
The invention discloses a high-sensitivity oil abrasive particle online monitoring system and a monitoring method, wherein the monitoring system comprises a sensor probe module, a driving module, a signal processing module and a signal acquisition module; the driving module generates an excitation signal to drive an excitation coil of the sensor probe; the signal processing module and the signal acquisition module are used for acquiring the induction coil signals of the sensor probe, amplifying, demodulating and low-pass filtering the induction coil signals, outputting metal particle signals, and finally transmitting the metal particle signals to the computer through the signal acquisition module. The invention effectively improves the acquisition precision of the online sensor and realizes the online detection of the tiny metal particles under the conditions of large drift diameter and high flow rate; the method can be applied to the on-line detection of the metal abrasive particles in the lubricating system of the aeroengine lubricating oil system and other mechanical equipment lubricating systems.
Description
Technical Field
The invention relates to the technical field of mechanical equipment state online monitoring, in particular to a high-sensitivity oil abrasive particle online monitoring system and a monitoring method.
Background
Fault detection and condition monitoring of machines are important methods for maintaining machine equipment operational performance and extending service life. Wear is one of the important factors affecting the service life of the machinery and causing failure. During the operation of the mechanical equipment, the generated metal abrasive particles can circulate with the lubricating oil, and the abrasion condition of the mechanical equipment can be evaluated by detecting parameters such as the size, the number and the like of the metal abrasive dust in the lubricating oil. The existing detection technology mainly comprises an online detection method and an offline detection method. The off-line detection method has the characteristics of long detection period, high cost and incapability of detecting equipment in real time, and has certain limitation in industrial application. The online detection method mainly comprises the following six types: optical, capacitive, resistive, ultrasonic, X-ray, and inductive methods. The optical method is affected by bubbles in the lubricating oil with very poor reliability. The capacitive or resistive method may cause oil degradation, and as time passes, the detection accuracy may also decrease. The accuracy of the ultrasonic process is affected by the viscosity, flow rate and mechanical vibration of the oil. The X-ray method has high detection precision, but the equipment is complex. The induction type metal abrasive particle detection method has the advantages of simple structure, convenience in installation, no influence of oil quality, capability of distinguishing ferromagnetic metal particles from nonferromagnetic metal particles and the like, and a great deal of researches are carried out on the method by researchers. However, in order to improve the detection accuracy of the inductive sensor, researchers generally use a micro-channel sensor, which seriously affects the application of the micro-channel sensor in practical engineering.
Therefore, how to improve the detection accuracy of the induction sensor under the conditions of large pipe diameter and high flow rate is a problem to be solved.
Disclosure of Invention
In order to solve the problem that the detection precision of an induction type sensor in the prior art is low under the conditions of large pipe diameter and high flow rate, the invention provides a high-sensitivity oil abrasive particle online monitoring system and a monitoring method, which realize the detection of tiny metal particles under the large pipe diameter and solve the problems in the prior art.
In order to achieve the above purpose, the present invention provides the following technical solutions: the high-sensitivity oil abrasive particle on-line monitoring system comprises a sensor probe module, a driving module, a signal processing module and a signal acquisition module; the driving module consists of a signal generator and a power amplifier and is used for generating an excitation signal to drive the excitation coil; the sensor probe module consists of two groups of excitation coils and two groups of induction coils, wherein the excitation coils are reversely connected in parallel, the induction coils are connected in series in the forward direction, and sinusoidal excitation signals are loaded on the two excitation coils of the sensor; the signal processing module amplifies, demodulates and filters the received induction signal in a low-pass way and outputs a metal particle signal; and the signal acquisition module carries out analog-digital conversion on the output metal particle signals and transmits the analog-digital conversion to a computer.
Further, the sensor probe module comprises a coil framework, an exciting coil E1, an exciting coil E2, an induction coil S1, an induction coil S2, an exciting resonance capacitor Ce and an induction resonance capacitor Cs.
Further, the exciting coil E1, the exciting coil E2, the induction coil S1 and the induction coil S2 are all wound on a coil framework;
the induction coil S1 and the induction coil S2 are wound in the same direction, are respectively wound in coil grooves on two sides of the framework, and are connected in series;
the exciting coil E1 and the exciting coil E2 are reversely wound, are respectively wound on the outer sides of the two induction coils S1 and S2, and are connected in parallel;
the induction resonance capacitor Cs is connected with the induction coils after being connected in series in parallel; the excitation resonance capacitor Ce is connected in parallel with the excitation coil after being connected in parallel.
Further, the induction coil S1 and the induction coil S2 are wound by high-temperature-resistant enameled wires with the diameter of 0.1mm, and the number of turns is 400.
Furthermore, the exciting coil E1 and the exciting coil E2 are wound by high-temperature-resistant enameled wires with the diameter of 0.2mm, and the number of turns is 300.
Furthermore, the coil framework is processed by alumina ceramic, and has good heat resistance and low heat conduction efficiency.
Further, the driving module specifically comprises an STM32 singlechip excitation signal generation module and a power amplification module, and an output port of the driving module is connected with the excitation coil E1 and the excitation coil E2 to drive the sensor.
Further, the signal processing module comprises a primary amplifying module, a secondary amplifying module, a phase-locked amplifying module and a low-pass filtering module;
the primary amplifying module is connected with the induction coil S1, the induction coil S2 and the induction resonance capacitor Cs and is used for primary amplifying signals acquired by the induction coil;
the secondary amplifying module is used for carrying out secondary amplification on the signal output by the primary amplifying module;
the phase-locked amplifying module performs phase-locked amplifying on the output signal of the second-stage amplifying module to remove interference noise;
the low-pass filtering module filters the carrier signal demodulated and output by the phase-locked amplifying module and outputs a low-frequency metal particle signal.
Further, the signal acquisition module comprises an AD converter, and the metal particle signals output by the signal processing module are transmitted to the computer after being subjected to digital-to-analog conversion by the AD converter.
In addition, in order to achieve the above purpose, the present invention also provides the following technical solutions: an on-line monitoring method of high-sensitivity oil abrasive particles comprises the following steps:
firstly, generating sinusoidal excitation signals through a driving module, loading the sinusoidal excitation signals onto two excitation coils of a sensor probe module, and outputting induction signals after the other two induction coils and a resonance induction capacitor form a resonance circuit;
then, amplifying the received induction signals through a primary amplifying module and a secondary amplifying module in the signal processing module; carrying out phase-locking amplification demodulation and low-pass filtering on the amplified output signal to output a metal particle signal;
and finally, performing analog-to-digital conversion on the output metal particle signals through a signal acquisition module, and transmitting the metal particle signals to a computer.
The beneficial effects of the invention are as follows: the sensor for on-line monitoring of the oil abrasive particles has the characteristics of simple structure, strong anti-interference capability, high sensitivity and the like, is used in an on-line monitoring system of the oil abrasive particles, has a simple operation method, can effectively monitor the size and concentration of the metal abrasive particles in the oil in real time, realizes the detection of the tiny metal particles under the conditions of large pipe diameter and high flow rate, has good instantaneity, and can be widely applied to the on-line detection of the metal abrasive particles in lubricating systems of aeroengines and other mechanical equipment.
Drawings
FIG. 1 is a schematic diagram of an on-line monitoring system according to the present invention;
FIG. 2 is a schematic diagram of an equivalent circuit of a sensor probe module;
FIG. 3 is a schematic diagram of a sensor probe module configuration;
FIG. 4 is a schematic diagram of a driving module;
FIG. 5 is a schematic diagram of a signal processing module;
FIG. 6 is a voltage signal generated when 100 μm ferromagnetic metal particles pass through a sensor;
FIG. 7 is a voltage signal generated when 300 μm non-ferromagnetic metal particles pass through a sensor.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1-7, the present invention uses two groups of exciting coils to perform reverse winding, applies sine exciting signals with the same frequency and amplitude, the two exciting coils can generate periodically-changing magnetic fields with equal magnitudes and opposite directions in the inner space, the two induction coils are positioned in the two exciting coils, when no metal particles pass through the sensor, the magnitude of the induced electromotive force output by the two induction coils is equal, the direction is opposite, and the induced electromotive force output after the series connection is zero. Since the magnetic permeability of the ferromagnetic metal particles is far greater than that of air and lubricating oil, when the ferromagnetic metal particles pass through, the induced voltage of one of the induction coils is increased, so that the voltage of the induction coils is unbalanced, and the induced electromotive force is output. The magnetic permeability of the non-ferromagnetic metal particles is very close to that of air and lubricating oil, but the metal particles can generate an eddy current effect under an alternating magnetic field to generate a magnetic field opposite to an exciting magnetic field, so that when the non-ferromagnetic metal particles pass through, the induction voltage of one induction coil is reduced, unbalance of the voltage of the induction coil is caused, and the induction electromotive force opposite to that when the ferromagnetic metal particles pass through is output.
As shown in fig. 1, the present invention provides a technical solution: the high-sensitivity oil abrasive particle on-line monitoring system mainly comprises a sensor probe module, a driving module, a signal processing module and a signal acquisition module; the sensor probe module consists of an excitation coil E1, an excitation coil E2, an induction coil S1, an induction coil S2, an excitation resonance capacitor Ce and an induction resonance capacitor Cs, wherein the excitation coils are reversely connected in parallel, the induction coils are connected in series in the forward direction, and a sinusoidal excitation signal is loaded on the sensor excitation coil E1, the excitation coil E2 and the excitation resonance capacitor Ce; the driving module consists of a signal generator and a power amplifier and is used for generating an excitation signal to drive the sensor excitation coil; the signal processing module is used for amplifying, demodulating and low-pass filtering the received induction signals and outputting metal particle signals; and the signal acquisition module carries out analog-digital conversion on the output metal particle signals and transmits the analog-digital conversion to a computer.
In the above embodiment, as shown in fig. 2 and 3, the sensor probe module includes an excitation coil E1, an excitation coil E2, a resonant excitation capacitor Ce, an induction coil S1, an induction coil S2, a resonant induction capacitor Cs, and a bobbin. The induction coil S1 and the induction coil S2 are respectively wound in two wire slots of the coil skeleton, and the excitation coil E1 and the excitation coil E2 are respectively wound outside the induction coil S1 and the induction coil S2. The exciting coil E1 and the exciting coil E2 are reversely wound, the two ends of the exciting coil E1 and the exciting coil E2 in the same direction are connected in parallel, and the exciting coil E1 and the exciting coil E2 are connected in parallel with the resonance exciting capacitor Ce to form a resonance circuit, and the resonance circuit is connected with the driving module. One end of the induction coil S1 is connected with one end adjacent to the induction coil S2 to form a series connection, one end of the resonance induction capacitor Cs at the other end of the induction coil S1 is connected, the other end of the induction coil S2 is connected with the other end of the resonance induction capacitor Cs to form a resonance circuit and then output, and the resonance circuit is connected with the signal processing module.
In a preferred embodiment, induction coil S1 and induction coil S2 are wound with high temperature resistant enameled wire having a diameter of 0.1mm, and the number of turns is 400.
In a preferred embodiment, the excitation coil E1 and the excitation coil E2 are wound by high temperature resistant enameled wires with a diameter of 0.2mm, and the number of turns is 300.
In a preferred embodiment, since the temperature of the lubricant in operation is generally above 100 degrees, the coil former is machined from alumina ceramic in order to reduce the effect of the lubricant temperature on the sensor acquisition accuracy.
In the above embodiment, as shown in fig. 4, which is a schematic diagram of a driving module, an STM32 single-chip microcomputer signal generator is used to generate a 120kHz sinusoidal signal, the offset voltage is filtered by a high-pass filter, and the offset voltage is amplified by a power amplifier to output an excitation signal with an amplitude of ±10v, so as to drive an excitation coil.
In the above embodiment, in fig. 2, the resonance conditions of the capacitor Ce forming the resonance circuit with the excitation coil E1 and the excitation coil E2, and the capacitor Cs forming the resonance circuit with the induction coil S1 and the induction coil S2 are:wherein f is the frequency of the excitation signal, L is the inductance of the coil, and C is the resonance capacitance value.
In the above embodiment, as shown in fig. 5, the signal processing module includes a first-stage amplifying module, a second-stage amplifying module, a lock-in amplifying module, and a low-pass filtering module. The signal processing module is connected with the output end of the sensor induction coil. After the induction coil output signal is connected to the signal processing module, the first-stage amplifying module amplifies the signal by 500 times, the amplified output signal is connected to the second-stage amplifying module again, the signal is amplified by 20 times, the output signal is processed by the phase-locked amplifying module, wherein the phase-locked amplified reference signal (Ref) is obtained by shifting the excitation signal, and finally, the signal is transmitted to the signal acquisition module through low-pass filtering.
In the above embodiment, the signal acquisition module processes the signal by using an AD converter, and the signal output by the signal processing module is transmitted to the computer after being subjected to mode conversion processing by the AD converter.
The ferromagnetic metal particles with a diameter of 100 μm and the non-ferromagnetic metal particles with a diameter of 300 μm were passed through the sensor at a speed of 0.3m/s, and the voltage signals outputted from the sensor were shown in fig. 6 and 7, respectively.
Although the present invention has been described with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications may be made to the embodiments described, or equivalents may be substituted for elements thereof, and any modifications, equivalents, improvements and changes may be made without departing from the spirit and principles of the present invention.
Claims (8)
1. The high-sensitivity oil abrasive particle online monitoring system is characterized by comprising a sensor probe module, a driving module, a signal processing module and a signal acquisition module; the driving module consists of a signal generator and a power amplifier and is used for generating an excitation signal to drive the excitation coil; the sensor probe module consists of two groups of excitation coils and two groups of induction coils, wherein the excitation coils are reversely connected in parallel, the induction coils are connected in series in the forward direction, and sinusoidal excitation signals are loaded on the two excitation coils of the sensor; the signal processing module amplifies, demodulates and filters the received induction signal in a low-pass way and outputs a metal particle signal; the signal acquisition module carries out analog-digital conversion on the output metal particle signals and transmits the analog-digital conversion to a computer;
the sensor probe module comprises a coil framework, an excitation coil E1, an excitation coil E2, an induction coil S1, an induction coil S2, an excitation resonance capacitor Ce and an induction resonance capacitor Cs;
the exciting coil E1, the exciting coil E2, the induction coil S1 and the induction coil S2 are wound on a coil framework;
the induction coil S1 and the induction coil S2 are wound in the same direction, are respectively wound in coil grooves on two sides of the framework, and are connected in series;
the exciting coil E1 and the exciting coil E2 are reversely wound, are respectively wound on the outer sides of the two induction coils S1 and S2, and are connected in parallel;
the induction resonance capacitor Cs is connected with the induction coils after being connected in series in parallel; the excitation resonance capacitor Ce is connected in parallel with the excitation coil after being connected in parallel.
2. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the induction coil S1 and the induction coil S2 are wound by high-temperature-resistant enameled wires with diameters of 0.1mm, and the number of turns is 400.
3. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the exciting coil E1 and the exciting coil E2 are wound by high-temperature-resistant enameled wires with diameters of 0.2mm, and the number of turns is 300.
4. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the coil skeleton is processed by alumina ceramic, and has good heat resistance and low heat conduction efficiency.
5. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the driving module specifically comprises an STM32 singlechip excitation signal generation module and a power amplification module, and an output port of the driving module is connected with the excitation coil E1 and the excitation coil E2 to drive the sensor.
6. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the signal processing module comprises a primary amplifying module, a secondary amplifying module, a phase-locked amplifying module and a low-pass filtering module;
the primary amplifying module is connected with the induction coil S1, the induction coil S2 and the induction resonance capacitor Cs and is used for primary amplifying signals acquired by the induction coil;
the secondary amplifying module is used for carrying out secondary amplification on the signal output by the primary amplifying module;
the phase-locked amplifying module performs phase-locked amplifying on the output signal of the second-stage amplifying module to remove interference noise;
the low-pass filtering module filters the carrier signal demodulated and output by the phase-locked amplifying module and outputs a low-frequency metal particle signal.
7. The high-sensitivity oil abrasive particle online monitoring system according to claim 1, wherein: the signal acquisition module comprises an AD converter, and the metal particle signals output by the signal processing module are transmitted to the computer after being subjected to digital-to-analog conversion by the AD converter.
8. A monitoring method of the high-sensitivity oil abrasive particle online monitoring system according to any one of claims 1 to 7, characterized by comprising the following steps:
firstly, generating sinusoidal excitation signals through a driving module, loading the sinusoidal excitation signals onto two excitation coils of a sensor probe module, and outputting induction signals after the other two induction coils and a resonance induction capacitor form a resonance circuit;
then, amplifying the received induction signals through a primary amplifying module and a secondary amplifying module in the signal processing module; carrying out phase-locking amplification demodulation and low-pass filtering on the amplified output signal to output a metal particle signal;
and finally, performing analog-to-digital conversion on the output metal particle signals through a signal acquisition module, and transmitting the metal particle signals to a computer.
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