电感式磨粒在线监测传感器灵敏度提高方法
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摘要
电感式磨损颗粒在线监测传感器的研究所面临的主要瓶颈是传感器灵敏度与孔径之间存在矛盾,灵敏度较高的传感器一般采用微流道结构(孔径<1mm),最大允许流量小;而大孔径的传感器其灵敏度较低.为满足重型机械磨损状态在线监测的需求,研究了大孔径(7mm)的电感式磨粒监测传感器灵敏度提高方法.提出使传感器工作于全谐振状态,其中激励线圈工作于并联谐振状态,感应线圈工作于串联谐振状态,共同增强颗粒引起的传感器输出感应电动势.检测机理上建立了交变磁场中金属颗粒对磁场的扰动模型,考虑了颗粒在交变磁场中的涡流效应,提高了模型的实用性.实验表明谐振原理极大地提高了传感器的灵敏度,实现了直径75μm铁磁性颗粒和220μm非铁磁性颗粒的有效检测,初步满足了重型机械设备初期异常磨损阶段的在线监测需求.
The main technical bottleneck in the research of on-line inductive wear particles monitoring sensor lies in the contradiction between the sensor sensitivity and channel diameter.The sensor with high sensitivity generally adopts the micro-flow channel structure,leading to a small maximum allowable flow rate,while the sensor with large channel diameter has markedly lower sensitivity.To satisfy the requirements of online wear condition monitoring of heavy machinery,the sensitivity improvement method of large aperture inductive abrasive particle sensor is studied.It is proposed to make the sensor work in full resonance state,in which the excitation coil works in the parallel resonance state and the induction coil works in the series resonance state so as to jointly enhance the sensor output induced electromotive force caused by the wear particles.For the detection mechanism,aperturbation model of magnetic field caused by wear debris in the alternating magnetic field is established,which considers the eddy current effect of particles in alternating magnetic field and improves the practicability of the model.The experimental results show that the resonance mechanism largely increases the sensitivity of the sensor,which can successfully detect up to 75μm ferromagnetic particles and 220μm non-ferromagnetic particles,and satisfy the online monitoring requirements of initial abnormal wear stage of the heavy machineries.
The main technical bottleneck in the research of on-line inductive wear particles monitoring sensor lies in the contradiction between the sensor sensitivity and channel diameter.The sensor with high sensitivity generally adopts the micro-flow channel structure,leading to a small maximum allowable flow rate,while the sensor with large channel diameter has markedly lower sensitivity.To satisfy the requirements of online wear condition monitoring of heavy machinery,the sensitivity improvement method of large aperture inductive abrasive particle sensor is studied.It is proposed to make the sensor work in full resonance state,in which the excitation coil works in the parallel resonance state and the induction coil works in the series resonance state so as to jointly enhance the sensor output induced electromotive force caused by the wear particles.For the detection mechanism,aperturbation model of magnetic field caused by wear debris in the alternating magnetic field is established,which considers the eddy current effect of particles in alternating magnetic field and improves the practicability of the model.The experimental results show that the resonance mechanism largely increases the sensitivity of the sensor,which can successfully detect up to 75μm ferromagnetic particles and 220μm non-ferromagnetic particles,and satisfy the online monitoring requirements of initial abnormal wear stage of the heavy machineries.
引文
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[9]郭海林,王晓雷.基于平面线圈的磨粒监测传感器[J].仪表技术与传感器,2012(2):3-4.GUO Hailin,WANG Xiaolei.Study of wearing debris sensor based on planar coil[J].Instrument Technique and Sensor,2012(2):3-4.(In Chinese)
[10]LI C,LIANG M.Enhancement of oil debris sensor capability by reliable debris signature extraction via wavelet domain target and interference signal tracking[J].Measurement,2013,46(4):1442-1453.
[11]范红波,张英堂,陶凤和,等.电感式磨粒传感器中非铁磁质磨粒的磁场特性[J].传感器与微系统,2010,29(2):35-37.FAN Hongbo,ZHANG Yingtang,TAO Fenghe,et al.Magnetic characteristic of unferromagnetic wear debris in inductive wear debris sensor[J].Transducer and Microsystem Technologies,2010,29(2):35-37.(In Chinese)
[12]吴超,郑长松,马彪.电感式磨粒传感器中铁磁质磨粒特性仿真研究[J].仪器仪表学报,2011,32(12):2774-2780.WU Chao,ZHENG Changsong,MA Biao.Simulation study on the characteristic of ferromagnetic wear debris in inductive wear debris sensor[J].Chinese Journal of Scientific Instrument,2011,32(12):2774-2780.(In Chinese)
[13]范红波,张英堂,任国全,等.新型磨粒在线监测传感器及其试验研究[J].摩擦学学报,2010,30(4):338-343.FAN Hongbo,ZHANG Yingtang,REN Guoquan,et al.Experimental study of on-line monitoring sensor for wear particles in oil[J].Tribology,2010,30(4):338-343.(In Chinese)
[14]高震,郑长松,贾然,等.综合传动油液金属磨粒在线监测传感器研究[J].广西大学学报(自然科学版),2017,42(2):409-418.GAO Zhen,ZHENG Changsong,JIA Ran,et al.Study on online monitoring wear debris sensor of power shift-steering transmission[J].Journal of Guangxi University(Natural Science Edition),2017,42(2):409-418.(In Chinese)
[2]DAVIS J P,CARLETTA J E,VEILLETTE R J,et al.Instrumentation circuitry for an inductive wear debris sensor[C]//New Circuits and Systems Conference(NEWCAS),2012IEEE 10th International.IEEE,2012:501-504.
[3]DU L,ZHU X,HAN Y,et al.Improving sensitivity of an inductive pulse sensor for detection of metallic wear debris in lubricants using parallel LC resonance method[J].Measurement Science and Technology,2013,24(7):600-664.
[4]王志娟,赵军红,丁桂甫.新型三线圈式滑油磨粒在线监测传感器[J].纳米技术与精密工程,2015,13(2):154-159.WANG Zhijuan,ZHAO Junhong,DING Guifu.A novel online oil debris monitoring sensor with three coils[J].Nanotechnology and Precision Engineering,2015,13(2):154-159.(In Chinese)
[5]KIM B,HAN S,KIM K.Planar spiral coil design for a pulsed induction metal detector to improve the sensitivities[J].IEEE Antennas and Wireless Propagation Letters,2014,13:1501-1504.
[6]ZHANG X,ZHANG H,SUN Y,et al.Research on the output characteristics of microfluidic inductive sensor[J].Journal of Nanomaterials,2014(15):1-7.
[7]郑长松,李萌,高震,等.电感式磨粒传感器磨感电动势提取方法[J].振动、测试与诊断,2016,36(1):36-41.ZHENG Changsong,LI Meng,GAO Zhen,et al.An approach of extract inductive debris sensor weak signal[J].Journal of Vibration.Measurement&Diagnosis,2016,36(1):36-41.(In Chinese)
[8]张兴明,张洪朋,陈海泉,等.微流体油液检测芯片分辨率-频率特性研究[J].仪器仪表学报,2014,35(2):427-433.ZHANG Xingming,ZHANG Hongpeng,CHEN Haiquan,et al.Study on the resolution-frequency characteristic of microfluidic oil detection chip[J].Chinese Journal of Scientific Instrument,2014,35(2):427-433.(In Chinese)
[9]郭海林,王晓雷.基于平面线圈的磨粒监测传感器[J].仪表技术与传感器,2012(2):3-4.GUO Hailin,WANG Xiaolei.Study of wearing debris sensor based on planar coil[J].Instrument Technique and Sensor,2012(2):3-4.(In Chinese)
[10]LI C,LIANG M.Enhancement of oil debris sensor capability by reliable debris signature extraction via wavelet domain target and interference signal tracking[J].Measurement,2013,46(4):1442-1453.
[11]范红波,张英堂,陶凤和,等.电感式磨粒传感器中非铁磁质磨粒的磁场特性[J].传感器与微系统,2010,29(2):35-37.FAN Hongbo,ZHANG Yingtang,TAO Fenghe,et al.Magnetic characteristic of unferromagnetic wear debris in inductive wear debris sensor[J].Transducer and Microsystem Technologies,2010,29(2):35-37.(In Chinese)
[12]吴超,郑长松,马彪.电感式磨粒传感器中铁磁质磨粒特性仿真研究[J].仪器仪表学报,2011,32(12):2774-2780.WU Chao,ZHENG Changsong,MA Biao.Simulation study on the characteristic of ferromagnetic wear debris in inductive wear debris sensor[J].Chinese Journal of Scientific Instrument,2011,32(12):2774-2780.(In Chinese)
[13]范红波,张英堂,任国全,等.新型磨粒在线监测传感器及其试验研究[J].摩擦学学报,2010,30(4):338-343.FAN Hongbo,ZHANG Yingtang,REN Guoquan,et al.Experimental study of on-line monitoring sensor for wear particles in oil[J].Tribology,2010,30(4):338-343.(In Chinese)
[14]高震,郑长松,贾然,等.综合传动油液金属磨粒在线监测传感器研究[J].广西大学学报(自然科学版),2017,42(2):409-418.GAO Zhen,ZHENG Changsong,JIA Ran,et al.Study on online monitoring wear debris sensor of power shift-steering transmission[J].Journal of Guangxi University(Natural Science Edition),2017,42(2):409-418.(In Chinese)