Motion simulation analysis of wear debris in an integrated detection unit for lubricating oil

Abstract

Accurate wear debris detection is vital for diagnosing engine wear. However, due to uncertainties in debris behavior, size, and operating conditions, identifying different materials with a single sensor is challenging. To improve sensitivity and accuracy, we propose an integrated detection unit for wear debris in lubricating oil, emphasizing multifunction integration and active intervention. This unit includes a static mixer, a flared transition zone, and a sensor-equipped detection zone. Parametric analysis reveals that debris mixed in the static mixer tends to aggregate toward the center, forming three distinct distribution rings at the detection unit's outlet. A 90° blade angle and a 1:1 aspect ratio enhance the difference in debris quantity between inner and outer rings. To enhance detection reliability, installing capacitive sensors at the front and electromagnetic sensors at the rear of the detection zone can improve the accuracy of detecting different materials debris. This concept offers a multifunctional solution for precise wear debris detection, addressing complex wear scenarios in engines.