An Oil Wear Particles Inline Optical Sensor Based on Motion Characteristics for Rotating Machines Condition Monitoring

Abstract

Since inline monitoring method has the advantages of no sampling, being real-time, no human intervention, and low error, this paper innovatively proposes to study the inline monitoring of wear particles in an oil pipeline, from the perspective of the different motion characteristics of the particles. In this paper, an inline optical sensor was designed and developed by studying the velocity characteristics of different particles through theoretical calculations, numerical simulations, and experimental analysis. First, an equation for particle motion was statistically established, based on the forces acting on wear particles in an oil-filled vertical tube. Then a finite element model of particle motion in a full-flow oil pipeline was created, to simulate particle motion with various diameters, densities, locations, and shapes. Finally, the results of the theoretical study were effectively applied to design an inline optical monitoring sensor, and the experimental validation results demonstrated that the inline sensor has excellent suitability for monitoring wear particles. This study has significance for the safe operation of large rotating machinery.

Numerical Approach and Verification Method for Improving the Sensitivity of Ferrous Particle Sensors with a Permanent Magnet

“…These particles usually contain ferrous, non-ferrous, and non-metal debris such as ceramics and polymers. To measure wear particles, wear particle sensors commonly utilize inductance- and capacitance-based methods [ 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 ], acoustic methods based on ultrasonic transducers [ 20 , 21 , 22 ], optical methods [ 23 , 24 , 25 , 26 ], magnetic methods [ 27 , 28 ], and a method based on a combination of a permanent magnet and inductance [ 29 ]. Among them, ferrous particle sensors are widely used to diagnose machine condition because machines are made of iron as their main component.…”

Assessment of Condition Diagnosis System for Axles with Ferrous Particle Sensor

“…Wear particle sensors commonly utilize inductance and capacitance-based methods [ 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 ], acoustic methods based on ultrasonic transducers [ 22 , 23 ], optical methods [ 24 , 25 , 26 ], and a method based on a combination of a permanent magnet and inductance [ 27 ], as shown in Figure 2 . Sensors for measuring wear particles are being developed in various ways, but most of them have been developed based on inductance and capacitance.…”

A Critical Review of On-Line Oil Wear Debris Particle Detection Sensors

“…Electrical on-line oil wear debris detection sensors mainly include three typical sensors: inductive, capacitive, and resistive [23]. Non-electrical on-line oil wear debris detection sensors mainly include image processing, optical, and ultrasonic sensors [24][25][26]. In marine engineering, selecting the appropriate type of on-line oil wear debris detection sensor depends on factors such as the type of machinery, the specific wear particles of concern, and the desired sensitivity and accuracy [27,28].…”