CN103308431B - Sensor for monitoring metal abrasive particles in oil liquid on line and application method for sensor - Google Patents
Sensor for monitoring metal abrasive particles in oil liquid on line and application method for sensor Download PDFInfo
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- 238000005461 lubrication Methods 0.000 abstract description 3
- 239000003921 oil Substances 0.000 description 37
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- 239000006061 abrasive grain Substances 0.000 description 9
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- 239000010721 machine oil Substances 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
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Abstract
本发明的用于在线监测油液金属磨粒的传感器为互感式传感器，包括激励线圈和感应线圈，在用磁惰性材料制成的骨架中心设置可以通过油液的油路，激励线圈和感应线圈同轴绕制在骨架上，感应线圈位于激励线圈与骨架之间，感应线圈的轴向长度为激励线圈轴向长度的1/4~1/2，感应线圈与激励线圈的轴向中点重合。传感器采用并联测量结构实现零位补偿与调节，结构简单，灵敏度高，线性度好，抗干扰能力强。将传感器应用于在线监测油液金属磨粒，操作方便，实时性好，测量精度高，监测结果准确可靠。可广泛运用于军用和民用领域，包括各种飞机、舰船及汽车等机械设备的润滑系统的油液污染程度、磨损监测及故障监测诊断，避免安全事故的发生。
The sensor used for on-line monitoring of oil metal abrasive particles of the present invention is a mutual inductance sensor, including an excitation coil and an induction coil, and an oil circuit that can pass through the oil, an excitation coil and an induction coil is arranged in the center of the skeleton made of magnetically inert material Coaxially wound on the frame, the induction coil is located between the excitation coil and the frame, the axial length of the induction coil is 1/4~1/2 of the axial length of the excitation coil, and the axial midpoint of the induction coil and the excitation coil coincides . The sensor adopts a parallel measurement structure to realize zero compensation and adjustment, with simple structure, high sensitivity, good linearity and strong anti-interference ability. The sensor is applied to online monitoring of oil and metal abrasive particles, which is easy to operate, good in real time, high in measurement accuracy, and accurate and reliable in monitoring results. It can be widely used in military and civilian fields, including oil pollution level, wear monitoring and fault monitoring and diagnosis of lubrication systems of various aircraft, ships and automobiles, so as to avoid safety accidents.
Description
技术领域 technical field
本发明涉及机械设备状态监测，具体是其中的油液分析技术，更具体是用于在线监测油液金属磨粒的传感器及其应用方法。 The invention relates to mechanical equipment state monitoring, in particular to the oil analysis technology therein, and more specifically to a sensor for on-line monitoring of oil metal abrasive grains and an application method thereof.
背景技术 Background technique
设备磨损失效是最常见的失效形式，机械设备70%以上的故障与磨损有关，通过对油液的监测和分析所获得的参数能很好的判断设备的润滑磨损状态。它是近十几年来迅速发展起来的用于机械设备状态监测的新技术，尤其在发动机、齿轮传动、轴承系统、液压系统等方面，该技术取得了显著的效益，因而在国内外得到高度重视。目前在工业发达的国家中，油液分析技术正在或已经成为机械设备状态监测及故障诊断的不可缺少的方法之一，占有重要地位。油液分析技术分为离线式和在线式。传统的离线式主要集中在光谱分析、铁谱分析、颗粒计数、油品理化分析等方面。在线式检测系统采用的分析原理主要有电磁法、X射线能谱、静电法和光电法等。与在线式机器油液分析相比, 与在线式机器油液分析相比, 离线式机器油液分析具有很高的监测精度。但是实验室分析费时较长(需要采集、传送、处理样品和等待分析结果)和检测成本高。且在比较长的分析时间里, 机器系统里的油液质量在离线分析过程中变差而导致系统损坏。因此离线式存在工作量大、不能实时反应油液的特征、会造成迟判误判以及检测仪器成本高的缺点。监测机械设备从磨损到失效是一个量变到质变的过程, 而这个过程发生的时间是未知的, 所以必须要时时刻刻对油液进行在线监测才不会使得油液的监测充满偶然性。油液在线监测很好克服了传统的实验室离线分析方法成本高、操作复杂、测量样本点有限的不足的缺陷，成为新一代油液监测技术发展的主要方向。而油液在线监测具有很多干扰因素，要想及时发现问题就必须具备很高的监测精度。 Equipment wear failure is the most common form of failure. More than 70% of mechanical equipment failures are related to wear. The parameters obtained by monitoring and analyzing the oil can well judge the lubrication and wear state of the equipment. It is a new technology for mechanical equipment condition monitoring that has developed rapidly in the past ten years. Especially in the aspects of engines, gear transmissions, bearing systems, hydraulic systems, etc., this technology has achieved remarkable benefits, so it has been highly valued at home and abroad. . At present, in industrially developed countries, oil analysis technology is becoming or has become one of the indispensable methods for mechanical equipment condition monitoring and fault diagnosis, and occupies an important position. Oil analysis technology is divided into offline and online. Traditional off-line methods mainly focus on spectral analysis, ferrographic analysis, particle counting, oil physical and chemical analysis, etc. The analysis principles adopted by the online detection system mainly include electromagnetic method, X-ray energy spectrum, electrostatic method and photoelectric method. Compared with online machine oil analysis, offline machine oil analysis has a high monitoring accuracy. However, laboratory analysis takes a long time (need to collect, transfer, process samples and wait for analysis results) and high detection cost. And in a relatively long analysis time, the quality of the oil in the machine system deteriorates during the offline analysis process, resulting in system damage. Therefore, the off-line method has the disadvantages of heavy workload, inability to reflect the characteristics of the oil in real time, late judgment and misjudgment, and high cost of detection equipment. Monitoring mechanical equipment from wear to failure is a process from quantitative change to qualitative change, and the time of this process is unknown, so it is necessary to monitor the oil online all the time so as not to make the oil monitoring full of accidents. Oil on-line monitoring has overcome the shortcomings of traditional laboratory off-line analysis methods such as high cost, complicated operation, and limited measurement sample points, and has become the main direction for the development of a new generation of oil monitoring technology. On-line monitoring of oil has many interference factors, and it is necessary to have high monitoring accuracy in order to find problems in time.
发明内容 Contents of the invention
本发明的目的在于提供一种灵敏度高，线性度好，抗干扰能力强的用于在线监测油液金属磨粒的传感器。 The purpose of the present invention is to provide a sensor with high sensitivity, good linearity and strong anti-interference ability for on-line monitoring oil metal abrasive particles.
本发明的用于在线监测油液金属磨粒的传感器为互感式电感传感器，包括激励线圈和感应线圈，在用磁惰性材料制成的骨架中心设置可以通过油液的油路，在骨架上绕制同轴的激励线圈和感应线圈，感应线圈位于激励线圈与骨架之间，感应线圈的轴向长度为激励线圈轴向长度的1/4~1/2，感应线圈与激励线圈的轴向中点重合。 The sensor used for on-line monitoring of oil metal abrasive particles of the present invention is a mutual inductance sensor, including an excitation coil and an induction coil, and an oil circuit that can pass through the oil is arranged in the center of a skeleton made of magnetically inert material, and the skeleton is wound The coaxial excitation coil and induction coil are made. The induction coil is located between the excitation coil and the skeleton. The axial length of the induction coil is 1/4~1/2 of the axial length of the excitation coil. points coincide.
本发明应用ANSYS软件对螺线管线圈建模仿真，利用数值分析方法对传感器结构进行了研究，发现螺线管激励线圈产生的磁场强度分布情况，在螺线管线圈内部的中间区域形成近似均匀的磁场且该区域磁场最强，而在线圈端面磁场强度衰减到中心磁场强度的1/2，从中间沿轴线到两端的磁场强度不是均匀的，也不是线性衰减的，而是弧形衰减的。所以传感器的感应线圈必须绕在激励线圈的线圈中间，才使传感器具有最佳灵敏度和线性度。感应线圈的长度必须根据激励线圈产生的磁场的中间近似均匀的区域的长度来确定。 The present invention uses ANSYS software to model and simulate the solenoid coil, and uses the numerical analysis method to study the sensor structure, and finds that the distribution of the magnetic field intensity generated by the solenoid excitation coil forms an approximately uniform structure in the middle area inside the solenoid coil. And the magnetic field in this area is the strongest, and the magnetic field strength at the end of the coil is attenuated to 1/2 of the central magnetic field strength, and the magnetic field strength from the middle along the axis to both ends is not uniform, nor linear attenuation, but arc attenuation . Therefore, the induction coil of the sensor must be wound in the middle of the coil of the excitation coil, so that the sensor has the best sensitivity and linearity. The length of the induction coil must be determined according to the length of the central approximately uniform region of the magnetic field generated by the excitation coil.
为使传感器具有最佳灵敏度，使传感器输出具有很好的线性度，感应线圈的轴向长度的最佳值应为激励线圈轴向长度的1/4~1/2。 In order to make the sensor have the best sensitivity and the sensor output has good linearity, the optimal value of the axial length of the induction coil should be 1/4~1/2 of the axial length of the excitation coil.
本发明的另一个目的是将本发明的传感器应用于油液金属磨粒的在线监测。 Another object of the present invention is to apply the sensor of the present invention to on-line monitoring of oil metal abrasive particles.
使用本发明的传感器进行监测的主要步骤如下： The main steps of monitoring using the sensor of the present invention are as follows:
A.将两个相同的传感器的激励线圈L1和L2并联接入激励交流电场模块fd来实现零位补偿与调节，将两个感应线圈LS1和LS2反向串联并与两个等阻值的电阻R1和R2接成交流电桥，传感器输出两端连接信号调理模块，电容C和变位器RP串联在传感器一个输出端与信号调理模块之间； A. Connect the excitation coils L1 and L2 of the same sensor in parallel to the excitation AC electric field module fd to realize zero compensation and adjustment, connect the two induction coils LS1 and LS2 in reverse series and connect them with two resistors of equal resistance R1 and R2 are connected as an AC bridge, the sensor output is connected to the signal conditioning module, and the capacitor C and the positioner R P are connected in series between one output terminal of the sensor and the signal conditioning module;
B.油液从其中一个传感器的油路中通过，另外一个传感器不通入任何物质； B. The oil passes through the oil passage of one of the sensors, and the other sensor does not pass any substance;
C. 传感器的输出信号经过信号调理模块采集处理后，得到油液金属磨粒的有关参数。 C. After the output signal of the sensor is collected and processed by the signal conditioning module, the relevant parameters of the oil and metal abrasive particles are obtained.
为使监测结果准确，电阻R1远远大于感应线圈的等效阻抗。 In order to make the monitoring result accurate, the resistance R1 is much larger than the equivalent impedance of the induction coil.
激励线圈L1和L2并联接入激励交流电场模块fd，激励线圈被输入激励交流电场而产生交变磁场，感应线圈LS1和LS2由于磁场的变化产生的感应电动势输出。感应线圈LS1和LS2产生的感应电动势反向串联输出，并与两个阻值很大的固定电阻接成交流电桥输出。电容C和变位器RP用于交流电桥的平衡调节。当传感器中含有激励线圈和感应线圈的一个桥臂通过含有金属磨粒的油液而另一个不通过时，金属磨粒影响传感器的磁场强度，破坏电桥的平衡，感应线圈输出相应幅值的交流电压。当没有磨粒的油液通过传感器时，传感器的两个感应磁场线圈产生的电压相同，桥式电路输出为零。输出电压大小和金属磨粒浓度大小成正比，油液中含有的金属磨粒浓度越大，输出电压值越大。通过信号调理模块对输出信号采集和处理，达到对油液金属磨粒浓度在线监测的目的。当然后续处理还包括A/D转换和微处理器处理等一些常规的数据和结果处理步骤。 The excitation coils L1 and L2 are connected in parallel to the excitation AC electric field module fd, the excitation coil is input with the excitation AC electric field to generate an alternating magnetic field, and the induction coils LS1 and LS2 generate an induced electromotive force due to the change of the magnetic field. The induced electromotive force generated by the induction coils LS1 and LS2 is output in reverse series, and is connected with two fixed resistors with large resistance to form an AC bridge output. Capacitor C and shifter R P are used for balance adjustment of the AC bridge. When one of the bridge arms containing the excitation coil and the induction coil in the sensor passes through the oil containing metal abrasive particles while the other does not, the metal abrasive particles affect the magnetic field strength of the sensor, destroying the balance of the bridge, and the induction coil outputs a corresponding amplitude. AC voltage. When the oil without abrasive particles passes through the sensor, the voltage generated by the two induction magnetic field coils of the sensor is the same, and the output of the bridge circuit is zero. The output voltage is proportional to the concentration of metal abrasive particles, the greater the concentration of metal abrasive particles contained in the oil, the greater the output voltage value. The output signal is collected and processed by the signal conditioning module to achieve the purpose of online monitoring of the concentration of metal abrasive particles in the oil. Of course, subsequent processing also includes some conventional data and result processing steps such as A/D conversion and microprocessor processing.
输出信号的幅值与金属磨粒个数的关系描述如下： The relationship between the amplitude of the output signal and the number of metal abrasive particles is described as follows:
两感应线圈的感生电动势 和分别为： The induced electromotive force of the two induction coils and They are:
式中，为激励电流；为电源角频率；为LS1对L1的互感系数；为LS2对L2的互感系数。 In the formula, is the excitation current; is the angular frequency of the power supply; is the mutual inductance coefficient of LS1 to L1; for LS2 to L2 mutual inductance coefficient.
则输出电压为： Then the output voltage is:
金属磨粒进入传感器前，产生的电感为： Before the metal abrasive particles enter the sensor, the inductance generated is:
当时， when hour,
式中，为真空磁导率；表示激励线圈线圈的匝数；r表示磁惰性管的内径；L表示激励线圈轴向长度。 In the formula, is the vacuum permeability; Indicates the number of turns of the excitation coil; r indicates the inner diameter of the magnetically inert tube; L indicates the axial length of the excitation coil.
当一颗金属磨粒进入传感器时，产生的电感增量为： When a metal abrasive particle enters the sensor, the resulting inductance increment is:
式中，为金属磨粒相对磁导率；为金属磨粒半径；为金属磨粒轴向长度。 In the formula, is the relative magnetic permeability of metal abrasive grains; is the radius of the metal abrasive grain; is the axial length of the metal abrasive grain.
假设磨粒是圆形的，即2 ，则上式简化为： Assuming that the abrasive particles are round, that is, 2 , then the above formula simplifies to:
当有n颗磨粒进入传感器时，总的电感增量为： When there are n abrasive particles entering the sensor, the total inductance increment is:
所以，电感的变化率为： Therefore, the rate of change of inductance is:
因此，在传感器几何尺寸(r、L)确定的情况下，金属磨粒的相对磁导率、金属磨粒的数量n越大，则电感量变化越大，输出电压信号幅值也越大，即输出信号幅值与金属磨粒的数量n成比例。 Therefore, when the sensor geometry (r, L) is determined, the relative permeability of metal abrasive grains , The larger the number n of metal abrasive grains, the greater the change in inductance, and the greater the amplitude of the output voltage signal, that is, the output signal amplitude is proportional to the number n of metal abrasive grains.
本发明在线监测油液金属磨粒的传感器结构合理，灵敏度高，线性度好，抗干扰能力强。将本发明的传感器应用于在线监测油液金属磨粒，方法操作方便，实时性好，测量精度高，监测结果准确可靠。 The sensor for on-line monitoring oil metal abrasive particles of the invention has reasonable structure, high sensitivity, good linearity and strong anti-interference ability. The sensor of the present invention is applied to online monitoring of oil metal abrasive grains, and the method has the advantages of convenient operation, good real-time performance, high measurement precision and accurate and reliable monitoring results.
本发明的传感器及其在在线监测中的应用方法，可运用于军用和民用领域，包括各种飞机、舰船及汽车等机械设备的润滑系统的油液污染程度监测及故障监测诊断，避免由于磨损或者油液中磨粒过多不能及时发现和处理，而引起机械故障。 The sensor of the present invention and its application method in on-line monitoring can be applied to military and civilian fields, including oil pollution degree monitoring and fault monitoring and diagnosis of lubrication systems of mechanical equipment such as various aircraft, ships, and automobiles, so as to avoid Abrasion or excessive abrasive particles in the oil cannot be detected and dealt with in time, causing mechanical failure.
附图说明 Description of drawings
图1 传感器线圈结构图。 Figure 1 Structural diagram of the sensor coil.
图2 传感器测量原理图。 Figure 2 Schematic diagram of sensor measurement.
具体实施方式 Detailed ways
下面结合附图并通过具体实施方式来进一步详细说明本发明。 The present invention will be further described in detail below in conjunction with the accompanying drawings and through specific embodiments.
见图1。在线监测油液金属磨粒的传感器为互感式电感传感器，包括激励线圈和感应线圈，在磁惰性材料制成的骨架中心设置可以通过油液的油路，在骨架上绕制同轴激励线圈和感应线圈，感应线圈位于激励线圈与骨架之间，感应线圈的轴向长度为激励线圈轴向长度的1/3，感应线圈的与激励线圈的轴向中点重合，即在轴向上，感应线圈处于激励线圈的中部。 see picture 1. The sensor for online monitoring of oil and metal abrasive particles is a mutual inductance sensor, including an excitation coil and an induction coil. An oil circuit that can pass through the oil is set in the center of the skeleton made of magnetically inert material, and a coaxial excitation coil and a coil are wound on the skeleton. Induction coil, the induction coil is located between the excitation coil and the frame, the axial length of the induction coil is 1/3 of the axial length of the excitation coil, and the axial midpoint of the induction coil and the excitation coil coincides, that is, in the axial direction, the induction coil The coil is in the middle of the excitation coil.
见图2。使用上述传感器进行在线监测油液金属磨粒的主要步骤如下： See Figure 2. The main steps of using the above sensors to monitor oil metal abrasive particles online are as follows:
A.将两个相同的传感器的激励线圈L1和L2并联接入激励交流电场模块fd，将两个感应线圈LS1和LS2反向串联并与两个等阻值的电阻R1和R2接成交流电桥，传感器输出两端连接信号调理模块，电容C和电位器RP串联在传感器一个输出端与信号调理模块之间； A. Connect the excitation coils L1 and L2 of the same sensor in parallel to the excitation AC electric field module fd, connect the two induction coils LS1 and LS2 in reverse series and connect them with two equal resistance resistors R1 and R2 to form an AC bridge , the two ends of the sensor output are connected to the signal conditioning module, and the capacitor C and the potentiometer R P are connected in series between one output terminal of the sensor and the signal conditioning module;
其中的电阻R1远远大于感应线圈的等效阻抗。 The resistance R1 is much larger than the equivalent impedance of the induction coil.
B.油液从其中一个传感器的油路中通过，另外一个传感器不通入任何物质； B. The oil passes through the oil passage of one of the sensors, and the other sensor does not pass any substance;
C. 传感器的输出信号经过信号调理模块采集处理后，及时得到油液金属磨粒的有关参数：如油液中金属磨粒的浓度（粒数/升或毫克/升）、金属磨粒的相对磁导率以及金属磨粒的粒径。 C. After the output signal of the sensor is collected and processed by the signal conditioning module, the relevant parameters of the metal abrasive particles in the oil are obtained in time: such as the concentration of the metal abrasive particles in the oil (number of particles/liter or mg/liter), the relative Magnetic permeability and particle size of metal abrasive grains.
后续处理还包括A/D转换和微处理器处理等一些常规的数据和结果处理步骤。 Subsequent processing also includes some conventional data and result processing steps such as A/D conversion and microprocessor processing.
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