Wu Xianwei, Liu Hairui, Qian Zhi, Qian Zhenghua, Liu Dianzi, Li Kun, Wang Guoshuai
State Key Laboratory of Mechanics and Control of Mechanical Structures, College of Aerospace Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China.
School of Engineering, University of East Anglia, Norwich NR4 7TJ, UK.
Micromachines (Basel). 2023 Mar 17;14(3):669. doi: 10.3390/mi14030669.
Lubricants have the ability to reduce frictions, prevent wear, convey metal debris particles and increase the efficiency of heat transfer; therefore, they have been widely used in mechanical systems. To assess the safety and reliability of the machine under operational conditions, the development of inductive debris sensors for the online monitoring of debris particles in lubricants has received more attention from researchers. To achieve a high-precision, high-efficiency sensor for accurate prediction on the degree of wear, the equivalent circuit model of the sensor coil has been established, and its equations discovering the relationship between the induced voltage and excitation frequency have been derived. Furthermore, the influence of excitation frequencies and metal debris on the magnetic flux density has been analyzed throughout the simulations to determine the sensor magnetic field. In order to identify a frequency range suitable for detecting both ferrous and non-ferrous materials with a high level of sensitivity, the analytical analysis and experiments have been conducted to investigate the frequency characteristics of the developed inductive debris sensor prototype and its improved inspection capability. Moreover, the developed inductive debris sensor with the noticeable frequency characteristics has been assessed and its theoretical model has been also validated throughout experimental tests. Results have shown that the detection sensitivity of non-ferrous debris by the developed sensor increases with the excitation frequency in the range of 50 kHz to 250 kHz, while more complex results for the detection of ferrous debris have been observed. The detection sensitivity decreases as the excitation frequency increases from 50 kHz to 300 kHz, and then increases with the excitation frequency from 300 kHz to 370 kHz. This leads to the effective selection of the excitation frequency in the process of inspection. In summary, the investigation into the frequency characteristics of the proposed novel inductive debris sensor has enabled its broad applications and also provided a theoretical basis and valuable insights into the development of inductive debris sensors with improved detection sensitivity.
润滑剂具有减少摩擦、防止磨损、输送金属碎屑颗粒以及提高热传递效率的能力；因此，它们已广泛应用于机械系统中。为了评估机器在运行条件下的安全性和可靠性，用于在线监测润滑剂中碎屑颗粒的感应式碎屑传感器的开发受到了研究人员更多的关注。为了实现一种用于精确预测磨损程度的高精度、高效率传感器，已建立了传感器线圈的等效电路模型，并推导了其揭示感应电压与激励频率之间关系的方程。此外，通过模拟分析了激励频率和金属碎屑对磁通密度的影响，以确定传感器磁场。为了确定一个适合以高灵敏度检测铁磁性和非铁磁性材料的频率范围，已进行了分析分析和实验，以研究所开发的感应式碎屑传感器原型的频率特性及其改进的检测能力。此外，已对具有显著频率特性的所开发的感应式碎屑传感器进行了评估，并且其理论模型也通过实验测试得到了验证。结果表明，所开发的传感器对非铁磁性碎屑的检测灵敏度在50kHz至250kHz范围内随激励频率增加，而对铁磁性碎屑的检测结果则更为复杂。当激励频率从50kHz增加到300kHz时，检测灵敏度降低，然后在300kHz至370kHz范围内随激励频率增加。这使得在检测过程中能够有效地选择激励频率。总之，对所提出的新型感应式碎屑传感器频率特性的研究使其能够得到广泛应用，也为开发具有更高检测灵敏度的感应式碎屑传感器提供了理论基础和有价值的见解。
