JP2020197421A - Metal impurity inspection apparatus - Google Patents

Abstract

To provide a technique for detecting a magnetic material in a substance having viscosity, with a simple configuration.SOLUTION: A metal impurity inspection apparatus 100 for detecting metal impurities contained in a viscous substance that is a substance with viscosity comprises: a holding device 110 for holding the viscous substance having a constant thickness; a detection device 130 for detecting the metal impurities in the viscous substance; and a slide guide 120 for slidably guiding the holding device 110 on the detection device 130. The detection device 130 includes a plurality of coil sets 131 having oscillation coils 136 and reception coils 138 which are alternately disposed in a sliding direction of the holding device 110. The oscillation coils 136 generate AC magnetic fields. The reception coils 138 output magnetic field waveforms on the basis of the AC magnetic fields generated by the oscillation coils 136. The plurality of coil sets 131 are individually disposed at different positions in a direction orthogonal to a sliding direction on a sliding surface where the holding device 110 slides.SELECTED DRAWING: Figure 1

Description

The present invention relates to an inspection technique for a viscous substance such as grease. In particular, the present invention relates to bearings mainly used for rotating parts of large machines and grease inspection technology used for lubrication of bearings.

Due to the structure of bearings used in rotating parts of large machines such as elevators, the metals are worn by rubbing against each other, and are damaged or deteriorated over time. Therefore, regular inspection and maintenance are required. Bearings are usually filled with grease for lubrication and component protection. Therefore, it is not possible to directly confirm the deterioration state of the bearing surface. Therefore, in general, the state of the bearing is indirectly confirmed by collecting the grease and measuring the color of the grease and the iron powder content contained in the grease.

As a method for measuring the iron powder content used at this time, for example, Patent Document 1 states that "a first exciting portion formed by winding a first exciting coil around a core material and a second exciting portion formed around the core material". A second exciting part formed by winding an exciting coil, a detecting part formed by winding a detection coil around a core material, a first connecting part, a second connecting part, and a first exciting part. A sample that holds a high-frequency power supply connected to each exciting coil and a sample containing metal impurities so that the direction of the magnetic field generated by the coil and the direction of the magnetic field generated by the second exciting coil are opposite to each other. A metal impurity measuring device including a notch in which a holding portion is installed and a measuring portion for measuring an induced voltage or an induced current generated in a detection coil (abstract excerpt) is disclosed.

Japanese Unexamined Patent Publication No. 2019-2752

In the metal impurity measuring device disclosed in Patent Document 1, the grease is held in a tubular sample case. Then, two exciting parts and one detecting part are installed so as to surround the sample case.

In this metal impurity measuring device, two exciting parts generate magnetic fluxes so as to cancel each other out at the detecting part. When the grease to be measured does not contain iron powder, the induced voltage or induced current due to the magnetic flux is not generated in the detection unit. On the other hand, when iron powder is contained in the grease, the magnetic flux changes, and an induced voltage or an induced current is generated in the detection unit. By measuring this induced voltage or induced current, the iron powder concentration in the grease is measured.

However, in the case of the configuration of the metal impurity measuring device disclosed in Patent Document 1, the distance of the iron powder contained in the grease from the exciting portion differs depending on whether the distribution position is near the outer periphery of the sample case or near the center. , There is a difference in magnetic flux density. Therefore, even if the same amount of iron powder is contained, the change in the magnetic flux detected differs depending on the distribution position of the iron powder. Further, since the sample case has a tubular shape, three-dimensional measurement is required. Therefore, a structure for detecting magnetic flux on three axes (X, Y, Z) and an exciting current are required, which makes the device large-scale and expensive.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a technique for detecting metal impurities in a viscous substance with high accuracy with a simple structure.

The present invention is a metal impurity inspection device for detecting metal impurities contained in a viscous substance, which is a viscous substance, and is a holding device for holding the viscous substance at a constant thickness, and a holding device in the viscous substance. A detection device for detecting the metal impurities and a slide guide for guiding the holding device on the detection device in a slidable manner are provided, and the detection devices are alternately arranged in a direction in which the holding device slides. A plurality of coil sets having an oscillating coil and a receiving coil are provided, the oscillating coil generates an AC magnetic field, and the receiving coil outputs a magnetic field waveform based on the AC magnetic field generated by the oscillating coil as output data. Each of the plurality of coil sets is arranged at different positions in a direction orthogonal to the sliding direction on the sliding surface on which the holding device slides.

According to the present invention, metal impurities in a viscous substance can be detected with high accuracy with a simple structure. Issues, configurations and effects other than those described above will be clarified by the description of the following embodiments.

It is an overall block diagram of the metal impurity inspection apparatus of 1st Embodiment. (A) is an explanatory diagram for explaining the detection device of the first embodiment, and (b) and (c) are explanatory views for explaining the slide guide of the first embodiment, respectively. It is explanatory drawing for demonstrating the detail of the detection apparatus of 1st Embodiment. (A) and (b) are explanatory views for explaining the principle of the detection apparatus of 1st Embodiment. (A) is a block diagram of the analyzer of the first embodiment, and (b) is a functional block diagram of the analyzer of the second embodiment. It is explanatory drawing for demonstrating the usage method of the metal impurity inspection apparatus of 1st Embodiment. (A) to (c) are explanatory views for explaining an example of an output waveform of the first embodiment. (A) to (c) are display examples of the first embodiment, and (d) is an explanatory diagram for explaining the distribution of iron powder in grease inferred from the display example. (A) to (c) are display examples of the first embodiment, and (d) is an explanatory diagram for explaining the distribution of iron powder in grease inferred from the display example. It is explanatory drawing for demonstrating another display example of 1st Embodiment. (A) to (c) are output waveform examples for explaining the analysis process of the second embodiment. (A) to (b) are output waveform examples for explaining the analysis process of the second embodiment. It is an overall block diagram of the metal impurity inspection apparatus of 3rd Embodiment. It is explanatory drawing for demonstrating the arrangement of the detection device and the lighting device of 3rd Embodiment. It is an overall block diagram of the metal impurity inspection apparatus of the modification of 3rd Embodiment. (A) is an explanatory diagram for explaining a guide rail of a modified example of the third embodiment, (b) a detection device, and (c) an illumination device. It is explanatory drawing for demonstrating the detection apparatus of the modification of this invention. It is explanatory drawing for demonstrating the detection apparatus of the modification of this invention.

<< First Embodiment >>
The first embodiment of the present invention will be described with reference to the drawings. In the metal impurity inspection device of the present embodiment, a viscous substance such as grease is moved on a detection device in which a magnetic sensor is arranged to detect metal impurities in the substance. The viscous substance is encapsulated, for example, to have a uniform thickness. The magnetic sensor is configured so that, for example, the magnetic flux changes as the enclosed substance moves.

Hereinafter, this embodiment will be described with reference to the drawings. In the following description, the viscous substance (viscous substance) to be inspected will be described as grease, and the metal impurities will be described as iron powder.

[Overall configuration of inspection equipment]
FIG. 1 is an overall configuration diagram of the metal impurity inspection device 100 of the present embodiment. As shown in this figure, the metal impurity inspection device 100 of the present embodiment includes a holding device 110, a slide guide 120, a detection device 130, and an analyzer 140. The holding device 110 holds the grease 111 at a constant thickness. The slide guide 120 slides the holding device 110 on the detection device 130. The detection device 130 detects the iron powder in the grease 111 held by the holding device 110. The analyzer 140 analyzes the detection signal from the detection device 130.

Hereinafter, in the present embodiment, as shown in FIG. 1, a plane parallel to the upper surface of the detection device 130 is defined as an xy plane, and a direction perpendicular to the plane is defined as the z direction. Further, the direction in which the holding device is slid on the xy plane is the −x direction, and the direction orthogonal to the −x direction is the y direction. Hereinafter, the x direction is also referred to as a longitudinal direction, the y direction is also referred to as a width direction, and the z direction is also referred to as a vertical direction. The top and bottom in the z direction are as defined in the figure.

[Holding device]
The holding device 110 holds the grease 111 to be inspected in a substantially flat shape with a constant thickness. In the present embodiment, as shown in FIG. 1, the sealing bag 112 that encloses the grease 111 and the two upper and lower sandwiching plates 113 and 114 that are arranged parallel to the xy plane and at a constant interval in the z direction. And.

The upper and lower two sandwiching plates 113 and 114 are cover plates 113 arranged on the grease 111 so that the distance between the mounting plate 114 on which the grease 111 is placed and the mounting plate 114 is constant, respectively. .. When it is not necessary to distinguish between the two functions, they are called sandwich plates.

The distance between the sandwich plates 113 and 114 shall be extremely small so that the grease 111 is substantially flat. The grease 111 is sandwiched between the two sandwiching plates 113 and 114 and is maintained at a constant thickness.

One ends of the sandwich plates 113 and 114 may be connected with tape or the like so as not to separate from each other. Further, in order to keep the distance between the two sandwich plates 113 and 114 in the z direction constant, fixed legs or the like may be arranged between the two sandwich plates 113 and 114. The fixed legs are arranged at the four corners of the sandwich plate 114, for example.

For the encapsulation bag 112, for example, an inexpensive clear pocket with a zipper can be used. As a result, the grease 111 can be easily disposed of after the inspection.

[Detector]
When the grease 111 held by the holding device 110 contains iron powder, the detection device 130 detects the iron powder. Then, the detection result is output to the analyzer 140 as output data. In this embodiment, the holding device 110 detects iron powder in the grease 111 while sliding along the slide guide 120.

A view of the detection device 130 viewed from above is shown in FIG. 2 (a). The detection device 130 includes a plurality of coil sets 131a, 131b, 131c which are on a plane parallel to the xy plane and are arranged at different positions in the y direction. As shown in FIG. 2A, each coil set 131a, 131b, 131c is on a plane parallel to the xy plane, and the first oscillation coil 136a, the receiving coil 138, and the first coil set 131a, the receiving coil 138, and the first coil set 131a, 131b, and 131c are arranged in a row in the x direction. It includes a bi-oscillation coil 136b. Hereinafter, unless it is necessary to distinguish between them, the coil sets 131a, 131b and 131c are represented by the coil set 131.

The first oscillating coil 136a and the second oscillating coil 136b each generate alternating magnetic fields in opposite directions on the same plane. Further, the receiving coil 138 is arranged between the first oscillating coil 136a and the second oscillating coil 136b or in the vicinity thereof, and detects the alternating magnetic field generated by the first oscillating coil 136a and the second oscillating coil 136b. Hereinafter, when it is not necessary to distinguish between them, the first oscillation coil 136a and the second oscillation coil 136b are represented by the oscillation coil 136.

In the present embodiment, the plurality of coil sets 131 are arranged so that iron powder having the entire width in the y direction, which is the width direction of the holding device 110, can be detected.

Here, the details of the detection device 130 of this embodiment will be described. The detection device 130 of the present embodiment includes an AC generation unit 132 and a reception unit 133, as shown in FIG. 3, in addition to a detection unit having a plurality of coil sets 131a, 131b, 131c. The detection unit is formed, for example, in a substantially flat shape.

The alternating current generating unit 132 generates an alternating current having a predetermined frequency and supplies the alternating current to the first oscillating coil 136a and the second oscillating coil 136b of each coil set 131. The first oscillating coil 136a and the second oscillating coil 136b generate alternating magnetic fields of the same intensity in opposite directions by the alternating current supplied from the alternating current generating unit 132. In order to generate the alternating magnetic fields of the first oscillating coil 136a and the second oscillating coil 136b in opposite directions, for example, the winding directions of the respective coils may be reversed.

The receiving coil 138 outputs a magnetic field waveform (induced voltage or induced current) generated based on the alternating magnetic field generated by the first oscillating coil 136a and the second oscillating coil 136b to the receiving unit 133. Hereinafter, it will be described as assuming that the induced voltage is output.

In the present embodiment, the receiving coil 138 is arranged substantially in the middle of the first oscillating coil 136a and the second oscillating coil 136b as described above. Therefore, as shown in FIG. 4A, when there is nothing that disturbs the magnetic field in the surroundings, the magnetic field generated by the first oscillation coil 136a (represented by the magnetic field line B1) and the magnetic field generated by the second oscillation coil 136b (magnetic field line B2). (Represented by) is canceled at the position of the receiving coil 138. That is, there is no iron powder in the grease 111 held by the holding device 110. In this case, no induced voltage is generated.

On the other hand, if something that disturbs the magnetic field is unevenly present in the magnetic field, both magnetic fields are not completely canceled at the position of the receiving coil 138. For example, when a magnetic material passes through a magnetic field, the magnetic material itself is also magnetized to generate a magnetic field. Therefore, it is combined with the magnetic field generated by the oscillating coil 136, and the magnetic flux density increases. Then, an induced voltage is generated in the receiving coil 138 due to the magnetic field remaining without being canceled. For example, there is a case where the iron powder 111f is present in the grease 111 held by the holding device 110.

The receiving unit 133 detects the induced voltage generated in the receiving coil 138, performs signal processing such as amplification and AD / DC conversion, and outputs the output data to the outside. In this embodiment, transmission is performed to the analyzer 140. In the present embodiment, the receiving unit 133 outputs the induced voltage received from the receiving coil 138 in each coil set 131 to the outside as output data of the independent channels.

[Slide guide]
The slide guide 120 slidably supports the holding device 110 while keeping it close to the surface (upper surface) of the detection device 130 at a constant distance, and guides the holding device 110 in the −x direction. As shown in FIG. 2B, the slide guide 120 has two guide rails 121a and 121b arranged on both sides (both ends) of the detection device 130 in the y direction over the entire length in the x direction. Be prepared. The guide rails 121a and 121b are provided with a guide groove for guiding the holding device 110.

At this time, the thickness h1 of the grease 111 is obtained by the difference between the heights of the two sandwich plates 113 and 114 in the z direction, the sum of h3 and h4, and the height H of the guide groove in the z direction. .. The smaller the difference between H and h3 + h4, the thinner the thickness of the grease 111 at the time of detection, and the closer the grease 111 is to a flat surface.

[Analysis equipment]
The analyzer 140 analyzes the output data output from the detection device 130 and presents information indicating the presence or absence of iron powder to the user. In this embodiment, the output data is a temporal change in the induced voltage due to the presence of iron powder in the grease 111. The analyzer 140 presents to the user a mode of change in the induced voltage due to the presence of iron powder in the grease 111.

In order to realize this, the analyzer 140 of the present embodiment includes an information processing unit 141, a communication unit 142, an operation unit 143, and a display unit 144, as shown in FIG. 5A.

The communication unit 142 is connected to the detection device 130 by wire or wirelessly, and receives output data from the detection device 130.

The information processing unit 141 analyzes the output data. In the present embodiment, the analysis process is realized by the CPU 141a loading the program 141a, the memory 141b, and the storage device 141c, which are stored in the storage device 141c in advance, into the memory 141b and executing the program.

The operation unit 143 receives an operation instruction from the user. For example, a keyboard, a mouse, a touch panel, and the like.

The display unit 144 displays the processing result by the information processing unit 141. For example, an LCD (Liquid Crystal Display), a CRT (Cathode Ray Tube) display, and the like.

[how to use]
A method of using the metal impurity inspection apparatus 100 of the present embodiment having the above configuration will be described with reference to FIG. When used, an alternating magnetic field is generated in each oscillating coil 136.

First, the user encloses the grease 111 to be inspected in the encapsulation bag 112. Then, the sealing bag 112 is sandwiched between the sandwiching plates 113 and 114. As a result, the grease 111 is held by the holding device 110 in a substantially flat shape with a uniform thickness.

The user inserts the holding device 110 into the guide grooves of the guide rails 121 and 122 of the slide guide 120. Then, the holding device 110 is moved along the guide groove in the longitudinal direction (−x direction). As a result, the holding device 110 keeps the height in the z direction constant and slides in the −x direction on the slide surface which is the upper surface of the detection device 130. That is, the thickness h1 of the grease 111 is also kept substantially constant during the detection.

Further, the holding device 110 is moved until the total length of the sandwich plate 113 in the longitudinal direction (x direction) passes over the receiving coil 138 of any of the coil sets 131. As a result, the detection device 130 can detect the iron powder in the entire grease 111 sealed in the sealing bag 112 at a constant distance.

The receiving unit 133 of the detection device 130 outputs the detection result to the analyzer 140 according to the instruction of the user. For example, the detection result is output to the analyzer 140 from the timing when the holding device 110 is inserted until the user stops the holding device 110.

[result of analysis]
At this time, examples of graphs (output waveforms) displayed on the display unit 144 by the analyzer 140 based on the output data output from the reception unit 133 are shown in FIGS. 7 (a) to 7 (b). Here, examples of graphs generated based on the detection results from one coil set 131 are shown. However, as described above, the analyzer 140 generates a graph for each of the output data received from each coil set 131a, 131b, 131c, that is, for each channel, and displays each on the display unit 144.

In these figures, the vertical axis is the detected value (induced voltage (V)), and the horizontal axis is time. However, since the holding device 110 is moved along the longitudinal direction (x direction) of the slide guide 120, if the moving speed is known, the horizontal axis is the slide guide 120 of the holding device 110 using this moving speed. The position in the longitudinal direction (x direction) can be calculated.

FIG. 7A is an example of the output waveform 211 when the grease 111 does not contain iron powder. As shown in this figure, when iron powder is not contained in the grease 111, an induced voltage is not generated. This is because, as described above, the magnetic field generated by the oscillating coil 136 is not disturbed.

FIG. 7B is an example of the output waveform 212 when iron powder is contained only in a predetermined region in the x direction in the grease 111. In such a case, as shown in this figure, the induced voltage is generated only while the region of the grease 111 containing the iron powder passes over the receiving coil 138.

FIG. 7C is an example of the output waveform 213 when iron powder is contained in the entire x direction in the grease 111. In such a case, as shown in this figure, an induced voltage is generated while the grease 111 passes over the receiving coil 138.

The analyzer 140 of the present embodiment displays these output waveforms on the display unit 144. By observing this display, the user can grasp the change in the distribution of iron powder in the moving direction (−x direction) of the grease 111 in the sealing bag 112 along the slide guide 120.

Further, the analyzer 140 displays an output waveform obtained from each output data for each coil set 131 arranged in the width direction (y direction) of the detection device 130. Therefore, the user can also grasp the distribution of the iron powder in the grease 111 in the y direction from each displayed output waveform.

8 (a) to 8 (c) show a display example of the output waveform of each channel, and FIG. 8 (d) shows the distribution of iron powder in the grease 111 estimated from those output waveforms. Further, FIGS. 9 (a) to 9 (c) show other display examples of the output waveforms of each channel, and FIG. 9 (d) shows the distribution of iron powder in the grease 111 estimated from those output waveforms. Is shown.

For example, as shown in FIGS. 8 (a) to 8 (c), it is assumed that the output waveforms 221a, 221b, and 221c obtained from the respective detection results from the coil sets 131a, 131b, and 131c are obtained. That is, this is an example in which the induced voltage of the output waveform 221b generated based on the output data from the coil set 131b is changed only at a specific time.

Looking at such a display, the user sees such a display, and in the grease 111 in the encapsulation bag 112, iron powder is present only in a specific region in the x direction, which is the central region in the y direction and as shown in FIG. You can understand that it is included. This is the case, for example, when iron powder is mixed as a foreign substance when the grease 111 is filled.

Further, it is assumed that the output waveforms 222a, 222b, and 222c as shown in FIGS. 9 (a) to 9 (c) are obtained from the detection results of the coil sets 131a, 131b, and 131c. That is, this is an example in which a change in the induced voltage is observed in all the output waveforms generated based on the output data from each coil set 131a, 131b, 131c.

By looking at such a display, the user can grasp that iron powder is distributed throughout the grease 111 in the encapsulation bag 112 as shown in FIG. 9D. This is an example of a case where the grease 111 is filled for lubrication of the bearing portion and protection of parts, a case where the bearing is worn due to aged deterioration, and the like.

In this way, the user can grasp the distribution state of the iron powder in the grease 111 from the output waveform displayed on the display unit 144. That is, the user can grasp the distribution of iron powder in the grease 111 in the two-dimensional directions of the x direction and the y direction by the metal impurity inspection device 100 of the present embodiment.

As shown in FIG. 10, the output waveforms 223a, 223b, and 223c generated based on the outputs from the coil sets 131a, 131b, and 131c may be collectively displayed. As a result, the user can intuitively grasp the entire distribution of iron powder.

As described above, the metal impurity inspection device 100 of the present embodiment detects metal impurities (iron powder) contained in the viscous substance (grease 111) which is a viscous substance. Then, on the holding device 110 that holds the viscous substance (grease 111) at a constant thickness, the detection device 130 that detects the metal impurities (iron powder) in the viscous substance (grease 111), and the detection device 130. A slide guide 120, which is arranged and has a guide rail 121 for slidably guiding the holding device 110, is provided. The detection device 130 includes a plurality of coil sets 131 having oscillating coils 136 and receiving coils 138 that are alternately arranged in the direction in which the holding device 110 slides. The oscillating coil 136 generates an alternating magnetic field and receives the receiving coil. 138 outputs a magnetic field waveform based on the alternating magnetic field generated by the oscillating coil 136 as output data, and each of the plurality of coil sets 131 has a width direction (y) orthogonal to the sliding direction on the sliding surface on which the holding device 110 slides. It is placed in a different position in the direction).

As described above, the metal impurity inspection device 100 of the present embodiment is generated by sliding the holding device 110 that holds the grease 111 to a constant thickness along the slide guide 120 and the presence of iron powder in the grease 111. The iron powder in the grease 111 is detected by detecting the time change of the induced voltage. The detection device 130 is composed of an oscillating coil 136 that generates an alternating magnetic field and a receiving coil that detects an induced voltage due to the alternating magnetic field, which changes due to the presence of iron powder.

The metal impurity inspection device 100 of the present embodiment can detect iron powder in the grease 111 with such a simple configuration.

Further, the oscillating coil 136 of the coil set 131 includes a first oscillating coil 136a and a second oscillating coil 136b that generate alternating magnetic fields in opposite directions, and the receiving coil 138 includes a first oscillating coil 136a and a second oscillating coil 136b. It is placed in the middle of.

Therefore, when there is no iron powder in the grease 111, the alternating magnetic fields of the first oscillating coil 136a and the second oscillating coil 136b cancel each other out in the receiving coil 138. On the other hand, when iron powder is present in the grease 111, any alternating magnetic field remains and an induced voltage is generated. Therefore, the iron powder in the grease 111 can be detected with high accuracy. Further, it is not necessary to generate a large magnetic field by the oscillation coil 136, and the power consumption can be reduced.

Further, the metal impurity inspection device 100 of the present embodiment analyzes the output data output from the detection device 130, and presents the output waveform to the user as information indicating the presence or absence of the metal impurity (iron powder). Further prepare.

That is, according to the present embodiment, in the analyzer 140, the time change of the induced voltage generated by the presence of iron powder in the grease 111 is output as output data. Due to the arrangement of the coil set 131, when iron powder is not contained in the grease 111, the output waveform becomes substantially linear. On the other hand, if even a small amount of iron powder is contained, the output waveform will not be straight. Therefore, the user can easily grasp whether or not iron powder is contained in the grease 111 by observing such an output waveform.

Further, in the metal impurity inspection device 100 of the present embodiment, the holding device 110 is arranged on the mounting plate 114 on which the grease 111 is placed and the grease 111, and the distance between the mounting plate 114 becomes constant. A cover plate 113, which is held in such a manner, is provided. The slide guide 120 includes a guide rail 121 having a guide groove that guides the holding device 110 to the surface of the detection device 130 while approaching the surface of the detection device 130 at a constant distance.

Due to such a configuration, according to the present embodiment, the grease 111 is kept substantially flat during detection. In addition, the output data indicates the presence or absence of iron powder according to the position in the slide direction. Then, as described above, the coil sets 131 are arranged at different positions in the width direction (y direction), and the output data detected by each coil set 131 can be obtained.

As described above, according to the present embodiment, the grease 111 is thinly spread in a plane and brought close to the flat detection device 130 to detect iron powder on two axes (X, Y). That is, it is possible to inspect the concentration of iron powder contained in the grease 111 with a device having a simple structure for grasping the distribution of the two-dimensional iron powder in the grease 111.

<< Second Embodiment >>
Next, the second embodiment of the present invention will be described. In the present embodiment, the analyzer 140 analyzes the output of the detection device 130 and outputs a warning according to the distribution of iron powder.

The hardware configuration of the metal impurity inspection device 100 of this embodiment is the same as that of the first embodiment. Therefore, the description thereof is omitted here.

The information processing unit 141 of the analyzer 140 of the present embodiment analyzes the detection result by the detection device 130 as described above, and outputs a warning according to the analysis result. In the present embodiment, in order to realize this, the information processing unit 141 of the analyzer 140 of the present embodiment includes the content determination unit 151, the distribution calculation unit 152, and a warning output as shown in FIG. 5 (b). A unit 153 is provided. The image analysis unit 154 is a function of the third embodiment described later.

Each of these functions is realized by the CPU 141a loading the program stored in the storage device 141c in advance into the memory 141b and executing the program.

The content determination unit 151 specifies the maximum value (hereinafter, simply referred to as the maximum value) of the absolute value of the detection result (induction voltage) received from the detection device 130. Then, it is determined whether or not the specified maximum value is equal to or higher than a predetermined detection threshold value. Then, if it is equal to or higher than the detection threshold value, an instruction is output to the distribution calculation unit 152 to perform distribution analysis.

The detection threshold value is a threshold value provided for determining whether or not iron powder is contained in the grease 111. Therefore, a minimum value close to approximately 0 is set. The detection threshold value is stored in advance in the storage device 141c of the information processing unit 141.

The distribution calculation unit 152 analyzes the distribution of iron powder in response to an instruction from the content determination unit 151. In the present embodiment, the number of times that the above-mentioned detection threshold value and the predetermined threshold value are exceeded is calculated, and based on the number of times, which of the predetermined distribution characteristics corresponds to is specified, and the specified distribution characteristic is used as the analysis result. Output.

For example, the distribution calculation unit 152 first specifies the maximum value of the absolute value of the output data for each unit time (hereinafter, simply referred to as an extreme value). Then, in each unit time, it is determined whether or not the extreme value exceeds the detection threshold value, and whether or not it exceeds a predetermined distribution threshold value. Then, over the entire detection period, the number N1 of the unit time in which the extremum exceeds the detection threshold and the number N2 of the unit time in which the extremum exceeds the distribution threshold are counted, respectively.

The distribution threshold value is provided to determine the distribution mode of the iron powder in the grease 111, and is set to a value larger than the detection threshold value. The distribution threshold is set in advance by the user and stored in the storage device 141c.

Each number of times N1 and N2 and the distribution characteristic are associated with each other in advance and stored in the storage device 141c. For example, the distribution characteristics are determined by using the discrimination threshold values T1 and T2 that are set in advance for each number of times N1 and N2. The distribution calculation unit 152 specifies the distribution characteristics corresponding to each of the calculated times N1 and N2, so that the distribution calculation unit 152 obtains the distribution characteristics of the iron powder in the x direction.

Further, the distribution calculation unit 152 obtains the distribution characteristics of iron powder for each predetermined range in the y direction by performing the above processing on the output data (each channel) from each coil set 131a, 131b, 131c.

The processing of the content determination unit 151 and the distribution calculation unit 152 will be described with specific examples, taking as an example the case where the distribution characteristic of the iron powder is any one of FIGS. 11 (a) to 12 (b). Here, the detection threshold value is indicated by the alternate long and short dash line 241 and the distribution threshold value is indicated by the broken line 243.

For example, when the output waveform 231 shown in FIG. 11A is obtained, the content determination unit 151 determines that the specified maximum value is less than a predetermined detection threshold value. Therefore, no instruction is output to the distribution calculation unit 152 to perform the distribution analysis. Along with this, the distribution calculation unit 152 also does not perform distribution analysis, and does not give a warning output instruction to the warning output unit 153.

On the other hand, when the output waveform 232 shown in FIGS. 11 (b) to 12 (b) is obtained, the content determination unit 151 determines that the specified maximum value is equal to or higher than a predetermined detection threshold value. Therefore, an instruction is output to the distribution calculation unit 152 to perform the distribution analysis. Upon receiving the instruction, the distribution calculation unit 152 calculates N1 and N2 for each of them.

For example, the distribution calculation unit 152 calculates N1 as 3 times and N2 as 0 times for the output waveform 232 shown in FIG. 11B. Further, for the output waveform 233 shown in FIG. 11C, N1 is calculated as 3 times and N2 is calculated as 2 times. Further, for the output waveform 234 shown in FIG. 12A, N1 is calculated as 13 times and N2 is calculated as 0 times. For the output waveform 235 shown in FIG. 12B, the number of times N1 is calculated to be 7 times and the number of times N2 is calculated to be 0 times.

Here, it is assumed that three distribution characteristics D1, D2, and D3 are prepared in advance. For example, the distribution characteristic D1 has N1 of 1 or more and less than the discrimination threshold T1 and N2 is less than the discrimination threshold T2, and the distribution characteristic D2 has N1 of 1 or more and less than the discrimination threshold T1 and N2 of the discrimination threshold T2 or more. As for the distribution characteristic D3, N1 is set to be equal to or higher than the discrimination threshold value T1.

When the output waveform 232 shown in FIG. 11B is obtained, the distribution calculation unit 152 identifies it as the distribution characteristic D1 based on the above calculation result. Further, when the output waveform 233 shown in FIG. 11C is obtained, it is specified as the distribution characteristic D2 based on the above calculation result. Further, when the output waveform 234 shown in FIG. 12A is obtained and the output waveform 235 shown in FIG. 12B is obtained, it is specified as the distribution characteristic D3 based on the above calculation result. Then, the specified distribution characteristics are output to the warning output unit 153, respectively.

The warning output unit 153 outputs output information such as a warning based on the distribution analysis result of the distribution calculation unit 152 according to a predetermined rule.

For example, when the analysis result of at least one channel is the distribution characteristic D1, it can be seen that the iron powder in the region in the y direction corresponding to the channel in the grease 111 has the distribution as shown in FIG. 11A. means. In this case, the warning output unit 153 outputs a warning meaning that observation is required. Further, a message may be output indicating that a small amount of fine iron powder is contained.

Further, when the analysis result of at least one channel is the distribution characteristic D2, it is found that the iron powder in the region in the y direction corresponding to the channel in the grease 111 has the distribution as shown in FIG. 11B. means. In this case, the warning output unit 153 outputs a warning meaning that observation is required. Further, a message may be output indicating that a large amount of iron powder is contained and is likely to be mixed during the grease filling.

Further, when the analysis result of at least one channel is the distribution characteristic D3, the iron powder in the region in the y direction corresponding to the channel in the grease 111 is as shown in FIG. 12 (a) or FIG. 12 (b). It means that the distribution is good. In this case, the warning output unit 153 outputs a warning indicating that the bearing should be replaced or re-inspected. Further, a message may be output indicating that the iron powder is distributed throughout the grease 111 and that it can be determined that the bearing is likely to be worn over time.

The warning to be output for each distribution characteristic is predetermined and stored in a storage device 141c or the like.

As described above, the metal impurity inspection apparatus 100 of the present embodiment further warns the configuration of the first embodiment with the distribution calculation unit 152 that calculates the distribution of iron powder in the grease 111 and the warning according to the calculated distribution. A warning output unit 153 for output is further provided.

Therefore, according to the present embodiment, the user can receive a warning according to the distribution of iron powder in the grease 111 as well as the graph. As a result, the state of the grease 111 can be grasped more accurately, and the optimum treatment can be performed according to the state of the grease 111.

In the above embodiment, the content determination unit 151 first determines the maximum value, but this process may not be performed. In this case, the distribution calculation unit 152 analyzes all the received output data.

For example, in the case of the output waveform 231 shown in FIG. 11A, both N1 and N2 are calculated as 0. The distribution characteristic in such a case is defined as, for example, the distribution characteristic D0. Further, in the warning output unit 153, for example, a process of not outputting a warning or a process of performing an output meaning that it is normal is registered in association with the distribution characteristic D0. Then, when such a distribution characteristic is received, the associated processing is performed.

Further, in the present embodiment, the distribution of iron powder in the grease 111 is specified by the maximum value and the extreme value of the output data, but the present invention is not limited to this. For example, the content may be calculated and the distribution of iron powder in the grease 111 may be specified based on the calculated content.

The content is calculated, for example, by integrating the output data. For example, the unit content A is specified by performing detection using a sample grease containing a unit amount in advance. Then, how many times this unit content A is calculated is used as the content.

At this time, the distribution calculation unit 152 calculates the content for each unit time. As a result, the distribution calculation unit 152 quantitatively obtains the iron powder content for each predetermined range in the x direction, that is, the distribution of the iron powder in the x direction. Further, by calculating the content for each unit time for the output data from each coil set 131a, 131b, 131c, the distribution calculation unit 152 performs the content for each predetermined range in the y direction, that is, the y direction. Quantitatively obtain the distribution of iron powder.

Further, the distribution may be specified by, for example, pattern matching or the like. In this case, a plurality of output waveforms are registered in advance in association with the characteristic distribution of iron powder. The distribution calculation unit 152 matches the output waveform obtained from the output data with the registered pattern, identifies the closest pattern, and thereby identifies the distribution characteristics of the iron powder.

<< Third Embodiment >>
Next, a third embodiment of the present invention will be described. In the present embodiment, the metal impurity inspection device 100 of either the first embodiment or the second embodiment is provided with a camera, and an image of grease 111 to be inspected is further acquired. Hereinafter, a case where a camera is provided in the configuration of the first embodiment will be described as an example.

FIG. 13 is an overall configuration diagram of the metal impurity inspection device 101 of the present embodiment. As shown in this figure, the metal impurity inspection device 101 of the present embodiment includes the holding device 110, the slide guide 120, the detection device 130, and the analyzer 140, similarly to the metal impurity inspection device 100 of the first embodiment. , Equipped with. Further, a camera 170 and a lighting device 160 are provided.

Since the detection device 130 is the same as that of the first embodiment, the description thereof will be omitted.

The lighting device 160 irradiates the holding device 110 when the grease 111 held by the holding device 110 is photographed by the camera 170. Therefore, the lighting device 160 includes, for example, a lamp 161 such as an LED lamp.

The length (width) of the lighting device 160 in the y direction is the same as that of the detecting device 130. Further, as shown in FIG. 14, the lighting device 160 is provided so that the position in the y direction is the same as that of the detection device 130 and the upper surface thereof is flush with the upper surface of the detection device 130. Be done.

As shown in FIG. 14, the lamp 161 is arranged so that the entire surface of the holding device 110 can be irradiated.

The camera 170 is a photographing device that photographs the grease 111 held by the holding device 110. In the present embodiment, the camera 170 is attached to a fixed arm or the like, and is arranged above the lighting device 160 and the holding device 110, for example, as shown in FIG.

The slide guide 120 slides and supports the holding device 110 in the x direction while keeping the holding device 110 close to the upper surface of the detecting device 130 and the upper surface of the lighting device 160 which are flush with each other at a constant distance. The slide guide 120 includes two guide rails 122a and 122b, which are arranged on both sides of the detection device 130 and the lighting device 160 in the y direction over the entire length in the x direction, respectively. The guide rails 122a and 122b are provided with a guide groove for guiding the holding device 110. The configuration of the guide rails 122a and 122b guide grooves is the same as that of the first embodiment.

The holding device 110 slides on the detection device 130 and the lighting device 160 in the x direction by the slide guide 120. When the holding device 110 is located above the lighting device 160, the lighting device 160 irradiates the holding device 110 from below.

Similar to the first embodiment, the holding device 110 includes an encapsulating bag 112, a sandwich plate (cover plate) 113, and a sandwich plate (mounting plate) 114. However, in the present embodiment, the image is taken from above by the camera 170. Further, it is irradiated from below by the lighting device 160. Therefore, for the sealing bag 112, the cover plate 113, and the mounting plate 114, for example, a transparent material is used. In particular, for the cover plate 113 and the mounting plate 114, for example, an acrylic plate or the like is used.

The image of the grease 111 taken by the camera 170 is transmitted to the analyzer 140. The camera 170 and the analyzer 140 are connected by wire or wirelessly.

As in the first embodiment, the analyzer 140 analyzes the output data output from the detection device 130 and presents it to the user. In the present embodiment, the image of the grease 111 transmitted from the camera 170 is further presented to the user. Since the hardware configuration of the analyzer 140 is the same as that of the first embodiment, the description thereof will be omitted here.

Similar to the first embodiment, the user can obtain information such as the distribution of iron powder in the grease 111 from the graph generated from the detection result by the detection device 130, and by viewing the image taken by the camera 170. , Distribution information of iron powder in grease 111 can be obtained.

As described above, the metal impurity inspection device 101 of the present embodiment includes a camera 170, which is a photographing device for photographing the grease 111 held by the holding device 110, and the grease 111 when photographing the grease 111 with the camera 170. A lighting device 160 for irradiating light is further provided.

As a result, according to the present embodiment, in addition to the detection result by the detection device 130, an image of the grease 111 maintained in a flat shape can be obtained. Then, the state of the grease 111 can be further observed from the obtained image. Therefore, the state of the grease 111 can be grasped with higher accuracy by the plurality of outputs.

Further, in the metal impurity inspection device 101 of the present embodiment, the upper surface of the detection device 130 and the upper surface of the lighting device 160 are arranged on the same plane. Therefore, by sliding the holding device 110 with this surface as a sliding surface, the detection by the detection device 130 and the shooting by the camera 170 can be realized by one operation.

In this embodiment, the case where the camera 170 and the lighting device 160 are added to the configuration of the first embodiment has been described as an example, but as described above, the camera 170 and the lighting device 160 are added to the second embodiment. You may.

In this case, the analyzer 140 further includes an image analysis unit 154, as shown in FIG. 5 (b). The image analysis unit 154 analyzes the acquired image and outputs the result.

For example, the acquired image is binarized to specify the distribution position of iron powder. Alternatively, it may be binarized, the area of the iron powder distribution region may be calculated, and the content may be calculated. Further, the deterioration state of the grease may be determined from the color of the grease 111. The color used as the determination standard is set in advance and held in the analyzer 140.

<Modification example 1>
In the above embodiment, the lighting device 160 is arranged so that the upper surface of the detection device 130 and the upper surface of the lighting device 160 are flush with each other. However, the arrangement of the lighting device 160 is not limited to this. For example, the detection device 130 may be detachably configured and mounted on the lighting device 160 as needed.

The overall configuration diagram of the metal impurity inspection apparatus 102 of this modification is shown in FIG. As shown in this figure, the metal impurity inspection device 102 of the present embodiment includes a holding device 110, a slide guide 120, a detection device 130, an analyzer 140, a camera 170, and a lighting device 160.

Basically, the configuration having the same name as the third embodiment has the same function. However, in the present embodiment, the detection device 130 is detachably configured. Further, the slide guide 120 includes guide rails 123a and 123b having guide grooves arranged on both sides of the lighting device 160 in the y direction, respectively. Hereinafter, when it is not necessary to distinguish, the guide rail 123 is used as a representative.

As shown in FIG. 16A, the guide rail 123 has a first guide groove 124 for inserting and holding the detection device 130 and a holding device 110 as guide grooves on the surface (upper surface) of the detection device 130. It is provided with a second guide groove 125 that slidably supports and guides in the −x direction while being brought close to each other at a distance. The first guide groove 124 is provided closer to the lighting device 160 than the second guide groove 125.

When detecting the distribution of iron powder, the detection device 130 is inserted into the first guide groove 124. Then, the holding device 110 is inserted into the second guide groove 125 and slid in the −x direction to detect iron powder in the grease 111. On the other hand, when photographing the grease 111, the detection device 130 is removed. By removing the detection device 130, the holding device 110 inserted into the second guide groove 125 can be irradiated from the lighting device 160.

As shown in FIGS. 16 (b) and 16 (c), the configuration of the detection device 130 and the configuration of the lighting device 160 are the same as those of the third embodiment having the same name, respectively. Further, the height of the first guide groove 124 in the z direction is set to the minimum height into which the detection device 130 can be inserted. Further, the height of the second guide groove 125 in the z direction is set to the minimum height at which the holding device 110 can be slid.

With this configuration, according to the present modification, the device size in the x direction can be reduced.

<Modification 2>
In the third embodiment, the cover plate 113, which is a sandwich plate on the camera 170 side of the holding device 110, may be a filter that transmits only a specific wavelength. By using such a filter for the cover plate 113, the components of foreign substances contained in the grease 111 can be specified.

For example, the image analysis unit 154 photographs the grease in a state in which no foreign matter is contained in advance using a filter, and holds the grease as a reference image. Then, the grease 111 is photographed using the same filter, and the components are discriminated by the difference in the absorption rate between the obtained image and the reference image.

Further, a plurality of filters that transmit different wavelengths may be prepared, and an image of grease 111 may be acquired by each filter. In this case, the image analysis unit 154 identifies the component by calculating the ratio of the wavelength signals of each pixel.

<Modification example 3>
Further, a predetermined pattern may be provided on the mounting plate 114, which is a sandwich plate on the side of the lighting device 160 of the holding device 110. In this case, the analyzer 140 calculates the iron powder content based on the detection amount of the predetermined pattern in the image taken in this embodiment.

In each of the above embodiments and modifications, the number and location of the coil sets 131 installed in the detection device 130 are not limited. It may be arranged so that the entire width direction (y direction) of the holding device 110 can be detected. For example, as shown in FIG. 17, the coil set 131 may be further arranged at different positions in the x direction to fill the gap in the y direction. This further reduces measurement omissions.

Further, in each of the above-described embodiments and modifications, the power supplies of the detection device 130 and the lighting device 160 are not shown. The power source may be either a built-in or externally connected battery or an external power supply such as power purchase.

Further, for the detection device 130 of each of the above-described embodiments and modifications, for example, the handrail inspection device built in the handrail of the passenger conveyor shown in FIG. 18 may be used. In this handrail inspection device, the first oscillating coil and the second oscillating coil that generate alternating magnetic fields in opposite directions and the receiving coil located in the middle or the vicinity thereof are arranged in a row in the longitudinal direction on the bottom surface. This is a device that inspects the deterioration of the steel cord built in the handrail at a high SN ratio when a plurality of the coil sets are provided so as to be offset in the width direction and the handrail passes over the coil set.

In this way, by applying the existing device, a highly reliable device can be obtained at a low development cost.

Further, although the metal impurity inspection devices 100, 101, and 102 of each of the above-described embodiments and modifications include the analyzer 140, the analyzer 140 may not be provided. In this case, for example, the detection device 130 includes a CPU, a ROM, a RAM, and a communication unit. Then, the detection result may be temporarily held in the ROM or RAM and output to an external device as needed. The detection result is analyzed in an external device at the output destination.

In each of the above embodiments, each function of the analyzer 140 is realized by the CPU 141a executing a program, but the present invention is not limited to this. For example, all or part of the functions may be realized by hardware such as ASIC (Application Specific Integrated Circuit) and FPGA (field-programmable gate array).

Further, the present invention is not limited to the above-described embodiment, and includes various modifications. For example, the above-described embodiment is for explaining the present invention in an easy-to-understand manner, and the present invention is not necessarily limited to the one including all the configurations described in the above-described embodiment.

Further, in each drawing, control lines and information lines that are considered necessary for explanation are described, and not all control lines and information lines necessary for a product are necessarily described. In a real product, you can think of almost all the components as interconnected.

Further, the present invention may take various other application examples and modifications as long as it does not deviate from the gist of the present invention described in the claims.

100: Metal impurity inspection device, 101: Metal impurity inspection device, 102: Metal impurity inspection device,
110: Holding device, 111: Grease, 111f: Iron powder, 112: Encapsulation bag, 113: Sandwich plate (cover plate), 114: Sandwich plate (mounting plate),
120: Slide guide, 121: Guide rail, 121a: Guide rail, 121b: Guide rail, 122: Guide rail, 122a: Guide rail, 122b: Guide rail, 123: Guide rail, 123a: Guide rail, 123b: Guide rail, 124: 1st guide groove, 125: 2nd guide groove,
130: Detection device, 131: Coil set, 131a: Coil set, 131b: Coil set, 131c: Coil set, 132: AC generator, 133: Receiver, 136: Oscillation coil, 136a: First oscillation coil, 136b: Second oscillator coil, 138: receiver coil,
140: Analytical device, 141: Information processing unit, 141a: CPU, 141b: Memory, 141c: Storage device, 142: Communication unit, 143: Operation unit, 144: Display unit, 151: Content determination unit, 152: Distribution calculation Unit, 153: Warning output unit, 154: Image analysis unit,
160: Lighting device, 161: Lamp, 170: Camera,
211: Output waveform, 212: Output waveform, 213: Output waveform, 221a: Output waveform, 221b: Output waveform, 221c: Output waveform, 222a: Output waveform, 222b: Output waveform, 222c: Output waveform, 223a: Output waveform, 223b: Output waveform, 223c: Output waveform, 231: Output waveform, 232: Output waveform, 233: Output waveform, 234: Output waveform, 235: Output waveform, 241: Single point chain line, 243: Broken line

Claims (11)

A metal impurity inspection device that detects metal impurities contained in a viscous substance, which is a viscous substance.
A holding device that holds the viscous substance at a constant thickness,
A detection device that detects the metal impurities in the viscous substance, and
A slide guide that slides the holding device onto the detection device is provided.
The detection device includes a plurality of coil sets having oscillating coils and receiving coils arranged alternately in a sliding direction of the holding device.
The oscillating coil generates an alternating magnetic field and
The receiving coil outputs a magnetic field waveform based on the alternating magnetic field generated by the oscillating coil as output data.
A metal impurity inspection device, wherein each of the plurality of coil sets is arranged at different positions in a direction orthogonal to the sliding direction on the sliding surface on which the holding device slides. The metal impurity inspection apparatus according to claim 1.
The coil set
The oscillating coil includes a first oscillating coil and a second oscillating coil that generate alternating magnetic fields in opposite directions.
A metal impurity inspection device characterized in that the receiving coil is arranged between the first oscillating coil and the second oscillating coil. The metal impurity inspection apparatus according to claim 1.
A metal impurity inspection device, further comprising an analyzer that analyzes the output data output from the detection device and presents information indicating the presence or absence of the metal impurities to the user. The metal impurity inspection apparatus according to claim 1.
The holding device is
A mounting plate on which the viscous substance is placed and
A metal impurity inspection apparatus comprising: a cover plate arranged on the viscous substance and held so as to keep a constant distance from the above-mentioned mounting plate. The metal impurity inspection apparatus according to claim 1.
The slide guide is a metal impurity inspection device including a guide rail having a guide groove for guiding the holding device to the surface of the detection device while approaching the surface of the detection device at a constant distance. The metal impurity inspection apparatus according to claim 3.
The analyzer is a metal impurity inspection apparatus including a distribution calculation unit for calculating the distribution of the metal impurities. The metal impurity inspection apparatus according to claim 6.
The analyzer is a metal impurity inspection device, further comprising a warning output unit that outputs a warning according to the obtained distribution. The metal impurity inspection apparatus according to claim 1.
An imaging device that photographs the viscous substance held by the holding device, and
A metal impurity inspection device further comprising a lighting device that irradiates the viscous substance with light when the viscous substance is photographed by the photographing device. The metal impurity inspection apparatus according to claim 8.
A metal impurity inspection device characterized in that the upper surface of the detection device and the upper surface of the lighting device are arranged on the same plane. The metal impurity inspection apparatus according to claim 8.
The detection device is a metal impurity inspection device that is detachably provided on the lighting device. The metal impurity inspection apparatus according to claim 1.
The detection device is a metal impurity inspection device, which is a handrail inspection device for a passenger conveyor.