Abstract
Lubricants are of key importance for mechanical processing, and exist in nearly every mechanical system. When the equipment is in operation, debris particles will be generated in mechanical lubricants. The detection of debris particles can indicate the wear degree of machinery components, and provide prognosis warning for the system before the fault occurs. In this work, a novel type of inductive debris sensor consisting of two excitation coils and two sensing coils is proposed for online debris monitoring. The developed sensor was proven to be of high sensitivity through experimental verification. The testing results show that, using the designed sensor, ferrous metal debris with a size of 115 μm and nonferrous metal debris with a size of 313 μm in a pipe with an inner diameter of 12.7 mm can be effectively detected. Moreover, the proposed inductive debris sensor structure has better sensitivity at higher throughput and its design provides a useful insight into the development of high-quality sensors with superior performances.
Highlights
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The velocity of the metal debris passing through the sensor is fixed as 0.2 m/s
An obvious output signal can be observed when ferrous metal debris with a diameter of 150 μm passes through the sensor, which means the designed sensor can effectively detect the ferrous metal debris with a diameter larger than 150 μm
Summary
Fault detection and condition monitoring of machines are important methods to maintain operational performance and extend the service life of rotating and reciprocating machinery in many sectors such as machinery manufacturing, the transportation industry, and the military. The applications of these technologies can prevent the breakdown of critical system components and avoid unexpected production delays [1]. Detecting metal debris in the lubrication oil is a direct and dependable method for monitoring the condition of rotating and reciprocating machinery [2,3,4]. The metal debris retains a stable size and concentration in the lubrication oil. When there is abnormality the concentration and size of metal debris will increase [5,6,7]
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