Abstract
To improve the wear monitoring accuracy of steel tribo-pairs, a ferromagnetic particle sensor that consists of a magnetic loop with two cylindrical magnetic poles and one magnetic housing is proposed. The induction coil is placed inside the magnetic poles to shield against external electromagnetic interference. The air gap is designed to 1 mm between the two magnetic poles, where a rotational symmetric high-gradient static magnetic field will be generated under constant direct current (dc) drive. The sine-wave-like signal of one period will be induced when one ferromagnetic particle flows through the sensor. The working principle of the sensor and the internal magnetic field distribution is explained by establishing a mathematical model and finite element analysis (FEA). Furthermore, the results about the effects of coil length and position show that the output voltage is not sensitive to the axial mounting positions of the induction coil, and a shorter inductive coil produces a larger output voltage. By the oil dynamic monitoring experiment, the sensor can distinguish 13- $\mu \text{m}$ ferromagnetic particles in an oil tube of 10-mm inner diameter. With its high sensitivity to ferromagnetic particles, the sensor is suitable for online wear monitoring of steel tribo-pairs.
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