The electromagnetic wear particle detector has been widely studied due to its prospective applications in various fields. In order to meet the requirements of the high-precision wear particle detector, a comprehensive method of improving the sensitivity and detectability of the sensor is proposed. Based on the nature of the sensor, parallel resonant exciting coils are used to increase the impedance change of the exciting circuit caused by particles, and the serial resonant topology structure and an amorphous core are applied to the inductive coil, which improves the magnetic flux change of the inductive coil and enlarges the induced electromotive force of the sensor. Moreover, the influences of the resonance frequency on the sensitivity and effective particle detection range of the sensor are studied, which forms the basis for optimizing the frequency of the magnetic field within the sensor. For further improving the detectability of micro-particles and the real-time monitoring ability of the sensor, a simple and quick extraction method for the particle signal, based on a modified lock-in amplifier and empirical mode decomposition and reverse reconstruction (EMD-RRC), is proposed, which can effectively extract the particle signal from the raw signal with low signal-to-noise ratio (SNR). The simulation and experimental results show that the proposed methods improve the sensitivity of the sensor by more than six times.
The electromagnetic wear particles detection sensor has been widely studied due to its ability to monitor the wear status of equipment in real time. To precisely estimate the change of the magnetic energy of the sensor coil caused by the wear particles, the magnetic property models of wear particles under the alternating magnetic field was established. The models consider the hysteresis effect and the eddy current effect of the wear particles. The analysis and experimental results show that with the increase of the effective field frequency, the change of the magnetic energy caused by the wear particles gradually decrease, which makes the induced electromotive force output by the sensor reduce with the decrease of the particle speed, so a signal compensation method is presented to obtain a unified signal when the same wear particle passing through the sensor in different speeds. The magnetic coupling effect between the two adjacent wear particles is analyzed. The result illustrates that the change of the magnetic energy caused by the dual wear particles system is larger than the sum of the energy variation caused by two independent wear particles, and with the increase of the interparticle distance, the magnetic coupling effect gradually weakens and disappears.
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