Abstract
An inductive oil pollutant detection sensor based on a high-gradient magnetic field structure is designed in this paper, which is mainly used for online detection and fault analysis of pollutants in hydraulic and lubricating oil systems. The innovation of the sensor is based on the inductance detection method. Permalloy is embedded in the sensing region of the sensor, so that the detection area generates a high gradient magnetic field to enhance the detection accuracy of the sensor. Compared with traditional inductive sensors, the sensor has a significant improvement in detection accuracy, and the addition of permalloy greatly improves the stability of the sensor’s detection unit structure. The article theoretically analyzes the working principle of the sensor, optimizes the design parameters and structure of the sensor through simulation, determines the best permalloy parameters, and establishes an experimental system for verification. Experimental results show that when a piece of permalloy is added to the sensing unit, the signal-to-noise ratio (SNR) of iron particles is increased by more than 20%, and the signal-to-noise ratio of copper particles is increased by more than 70%. When two pieces of permalloy are added, the signal-to-noise ratio for iron particles is increased by more than 70%, and the SNR for copper particles is increased several times. This method raises the lower limit of detection for ferromagnetic metal particles to 20 μm, and the lower limit for detection of non-ferromagnetic metal particles to 80 μm, which is the higher detection accuracy of the planar coil sensors. This paper provides a new and faster online method for pollutant detection in oil, which is of great significance for diagnosing and monitoring the health of oil in mechanical systems.
Highlights
Condition monitoring and fault diagnosis of machinery are important in modern industrial contexts
Shi et al [14] designed a high-gradient magnetic field sensor based on the structure of the double-coil, which improved the detection accuracy of the double-planar coil and was able to identify 30 μm iron particles and 100 μm copper particles
The design of the new structure can effectively improve the magnetic induction intensity of the detection magnetic field, enhance the detection accuracy of the planar coil structure, and weaken the interference of the external magnetic field, so that the coil magnetic field is concentrated in the detection area
Summary
Condition monitoring and fault diagnosis of machinery are important in modern industrial contexts. Du et al [12] designed a resonant high-sensitivity detection unit with two-layer planar coils, which can effectively identify 50 μm iron particles. Shi et al [14] designed a high-gradient magnetic field sensor based on the structure of the double-coil, which improved the detection accuracy of the double-planar coil and was able to identify 30 μm iron particles and 100 μm copper particles. Ma et al [16] added an iron core to the inner hole of the single-layer planar coil, and used the high magnetic permeability of the iron core to increase the magnetic field strength of the sensor area, greatly improving the detection accuracy of the single-layer planar coil, allowing it to identify 50 μm ferromagnetic and 130 μm non-ferromagnetic particles. Weaken the interference of the external magnetic field, so that the coil magnetic field is concentrated in the detection area
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