This paper develops a dual-coil sensor integrated with
high-permeability materials based on inductive sensor technology to
detect wear particles in oil. This method is mainly used for online
detection and fault analysis of pollutants in hydraulic and
lubricating oil systems. The sensor innovatively embeds permalloy
into the sensing unit of the sensor to generate high gradient
magnetic field in the sensing area, consequently improving the
detection sensitivity of the sensor. The detection unit consists of
two pieces of permalloy and two plane coils. The permalloys have a
rectangular groove at the center, which is placed in line with the
inner hole of the coil, thereby forming the detection
area. Particles in the microchannel can be detected as they flow
through the detection area. The article theoretically analyzes the
working principle of the sensor and establishes a verification
experiment system. The experimental results show that after adding
permalloy to the sensing unit, the signal-to-noise ratio (SNR) of
iron particles is increased by more than 40%, and the SNR of copper
particles is increased by more than 30%. As the particle size
increases, the SNR decreases. Using this design, the range of the
lower limit detection for ferromagnetic metal particles increased to
10–15 μm, while that of non-ferromagnetic metal particles
increased to 60 μm. Compared with traditional inductive
sensors, the addition of permalloy greatly improves the sensor's
performance, which significantly boosts the sensitivity of the
dual-coil type sensor.
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