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WO2012162869A1 - 一种电感式磨粒监测装置及其测量单元 - Google Patents

一种电感式磨粒监测装置及其测量单元 Download PDF

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Publication number
WO2012162869A1
WO2012162869A1 PCT/CN2011/074755 CN2011074755W WO2012162869A1 WO 2012162869 A1 WO2012162869 A1 WO 2012162869A1 CN 2011074755 W CN2011074755 W CN 2011074755W WO 2012162869 A1 WO2012162869 A1 WO 2012162869A1
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WIPO (PCT)
Prior art keywords
inductive
monitoring device
cavity
measuring unit
insulated wire
Prior art date
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PCT/CN2011/074755
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English (en)
French (fr)
Inventor
张洪朋
孙玉清
李冬青
陈海泉
黄文�
Original Assignee
Zhang Hongpeng
Sun Yuqing
Li Dongqing
Chen Haiquan
Huang Wen
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Publication date
Application filed by Zhang Hongpeng, Sun Yuqing, Li Dongqing, Chen Haiquan, Huang Wen filed Critical Zhang Hongpeng
Priority to PCT/CN2011/074755 priority Critical patent/WO2012162869A1/zh
Publication of WO2012162869A1 publication Critical patent/WO2012162869A1/zh

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N15/00—Investigating characteristics of particles; Investigating permeability, pore-volume or surface-area of porous materials
    • G01N15/06—Investigating concentration of particle suspensions
    • G01N15/0656—Investigating concentration of particle suspensions using electric, e.g. electrostatic methods or magnetic methods
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/26—Oils; Viscous liquids; Paints; Inks

Definitions

  • the invention belongs to the technical field of oil liquid monitoring, and in particular relates to an inductive abrasive particle monitoring device and a measuring unit thereof. Background technique
  • the prior art provides an inductive abrasive particle monitoring device that actively monitors the device by monitoring wear particles in the oil of lubricating oil or other mechanical equipment, and prevents the device from being protected.
  • the failures and failures are widely used in engineering and transportation machinery.
  • Fig. 1 The principle of an inductive abrasive particle monitoring device provided by the prior art is shown in Fig. 1, which includes a measuring unit and an analysis module.
  • the measuring unit adopts a solenoid method, in particular, an insulated wire is wound around the insulating tube, and the two ends of the insulated wire are connected to the analysis module.
  • the inductive abrasive particle monitoring device is used to detect the oil, the oil to be tested flows through the insulating tube.
  • the wear particles in the oil to be tested pass through the measuring unit, the inductance of the measuring unit is changed, the ferromagnetic wear particles increase the inductance of the measuring unit, and the non-ferromagnetic wear particles reduce the inductance of the measuring unit.
  • the wear particles in the oil can be qualitatively and quantitatively detected.
  • the wall thickness of the insulating tube always has a large distance between the insulating tube and the wear particles to be tested, so that the sensitivity of the inductive abrasive particle monitoring device provided by the prior art is low and difficult. Achieve the diameter in
  • An object of the embodiments of the present invention is to provide an inductive abrasive particle monitoring device to solve the prior art.
  • the inductive abrasive particle monitoring device provided has a problem that the insulation tube has a large distance between the insulating tube and the wear particles to be tested due to the wall thickness of the insulating tube in the measuring unit, and the sensitivity is low.
  • an inductive abrasive particle monitoring device comprising a detection coil and an analysis module, the measurement unit comprising:
  • the insulated wire being fixed to the inner wall of the cavity in a spiral shape.
  • the inner wall of the cavity is provided with one end groove arranged in a spiral shape, and the insulated wire is fixed in the groove.
  • the cavity may be made of an insulating injection molded material.
  • the insulating injection molding material may be polydimethylsiloxane or polymethyl methacrylate.
  • the invention also provides a measuring unit of the inductive abrasive particle monitoring device, the measuring unit comprising: an insulated wire, the two ends of the insulated wire are connected to the analysis module;
  • the insulated wire being fixed to the inner wall of the cavity in a spiral shape.
  • the inner wall of the cavity is provided with one end groove arranged in a spiral shape, and the insulating wire is fixed in the groove.
  • the cavity may be made of an insulating injection molding material.
  • the insulating injection molding material may be polydimethylsiloxane or polymethyl methacrylate.
  • the present invention also provides a method of fabricating a measuring unit of the inductive abrasive particle monitoring device as described above, the method comprising the steps of:
  • the mold and the thin shaft are separated from the insulating injection molded material after curing, and the insulated wire is fixed to the inner wall of the insulating injection material as it is.
  • the insulating injection molding material may be polydimethylsiloxane or polymethyl methacrylate.
  • the cavity serves as a flow path of the liquid to be tested.
  • the liquid to be tested is in direct contact with the insulated wire.
  • the theoretical spacing between them is 0.
  • the wear particles in the liquid to be tested can be passed by more magnetic lines of force, and the inductance of the insulated wire changes more, thereby greatly improving the sensitivity of the monitoring, and detecting the wear particles having a diameter of 50 ⁇ m or less in the liquid to be tested. It is of great significance to the safe and reliable operation of machinery and equipment and personal safety.
  • FIG. 1 is a schematic diagram of an inductive abrasive particle monitoring device provided by the prior art
  • FIG. 2 is a schematic diagram of an inductive abrasive particle monitoring device provided by the present invention.
  • FIG. 3 is a flow chart of a manufacturing method of a measuring unit in the inductive abrasive particle monitoring device provided by the present invention.
  • Fig. 4 is a graph showing the relationship between the wear particle diameter and the inductance variation of the insulated wire when the inductive abrasive particle monitoring device provided by the present invention is used to detect wear particles below 70 microns.
  • Fig. 2 shows the principle of the inductive abrasive particle monitoring device provided by the present invention, and for the convenience of description, only the parts related to the present invention are shown.
  • the inductive abrasive particle monitoring device comprises a measuring unit and an analyzing module 13, wherein the measuring unit further comprises: an insulated wire, the two ends of the insulated wire are connected to the analysis module 13; and the cavity 12 through which the liquid to be tested flows
  • the insulated wire is fixed to the inner wall of the cavity 12 in a spiral shape.
  • the inner wall of the cavity 12 is provided with a section of the groove 11 arranged in a spiral shape, and the insulated wire is fixed in the groove 11.
  • the cavity 12 serves as a flow path of the liquid to be tested, and at this time, directly due to the liquid to be tested and the insulated wire Contact, with a theoretical spacing of zero.
  • the wear particles in the liquid to be tested can be passed by more magnetic lines of force, and the inductance of the insulated wire changes more, thereby greatly improving the sensitivity of the monitoring, and The detection of micron-scale wear particles in the liquid to be tested is of great significance for the safe and reliable operation and personal safety of the machine equipment.
  • the cavity 12 may be made of polydimethylsiloxane (PDMS) or polymethyl methacrylate (PMMA), and of course, may be made of other existing insulating injection molding materials;
  • the liquid to be tested is preferably a lubricating oil.
  • the present invention also provides a measuring unit of the inductive abrasive particle monitoring device as described above.
  • 3 is a flow chart of a manufacturing method of a measuring unit in the inductive abrasive grain monitoring device provided by the present invention.
  • step S101 the thin shaft wound with the insulated wire is fixed in a mold whose diameter depends on the diameter of the flow path of the liquid to be tested designed.
  • a liquid insulating injection molding material is injected into the mold, and the liquid insulating injection molding material in the mold is solidified by heating or the like.
  • the liquid insulating injection molding material is preferably polydimethylsiloxane (PDMS) or polymethyl methacrylate (PMMA).
  • step S103 the mold and the thin shaft are separated from the solidified injection molding material, and at this time, the insulated wire originally wound on the thin shaft is still fixed on the inner wall of the insulating injection material, the insulated wire The portion between them becomes the flow path of the liquid to be tested.
  • Fig. 4 is a view showing the relationship between the diameter of the wear particles and the amount of change in the inductance of the insulated wire when the above-described inductive abrasive particle monitoring device provided by the present invention is used to detect the abrasive particles below 70 microns.
  • the cavity 12 serves as a flow path of the liquid to be tested, and at this time, directly due to the liquid to be tested and the insulated wire Contact, with a theoretical spacing of zero.
  • the wear particles in the liquid to be tested can be passed by more magnetic lines of force, and the inductance of the insulated wire changes more, thereby greatly improving the sensitivity of the monitoring, and
  • the detection of wear particles with a diameter of 50 microns or less in the liquid to be tested is of great significance for the safe and reliable operation and personal safety of the machine equipment.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
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  • Physics & Mathematics (AREA)
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  • Pathology (AREA)
  • Dispersion Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Medicinal Chemistry (AREA)
  • Investigating Or Analyzing Materials By The Use Of Magnetic Means (AREA)
  • Measurement Of Length, Angles, Or The Like Using Electric Or Magnetic Means (AREA)

Abstract

公开了一种电感式磨粒监测装置。其中，所述监测装置包括测量单元以及分析模块。所述测量单元包括绝缘导线和供待测液体流过的腔体。所述绝缘导线的两端抽头连接分析模块，并且绝缘导线以螺旋状固定于腔体的内壁上。当利用所述监测装置对磨损微粒进行监测时，腔体作为待测液体的流道，并且由于待测液体与绝缘导线直接接触，其间的理论间距为0。所述监测装置能够提高监测的灵敏度，并且能够检测出待测液体中直径在50微米以下的磨损微粒，这对机器设备的故障监测和故障诊断有着重要意义。

Description

说 明 书
一种电感式磨粒监测装置及其测量单元
技术领域
本发明属于油液监测技术领域， 尤其涉及一种电感式磨粒监测装置及其测 量单元。 背景技术
各类机器设备在运行过程中， 必然会产生悬浮于润滑系统油液中的磨损微 粒， 大的磨损微粒会在短时间内造成设备的严重损坏， 磨损微粒是设备内部磨 损状态的重要信息载体， 因此， 及时准确的掌握油液中磨损微粒的情况对设备 的故障监测和故障诊断有着重要意义。
为此， 现有技术提供了一种电感式磨粒监测装置， 其通过对润滑油或其它 机械设备的油品中的磨损微粒进行监测， 而对设备起到主动预防性维护的作用， 防止设备的失效和故障， 被广泛应用到工程和交通机械等领域。
如图 1 示出了现有技术提供的电感式磨粒监测装置的原理， 其包括测量单 元和分析模块。 其中的测量单元采用螺线管方式， 具体是将绝缘导线缠绕在绝 缘管上， 该绝缘导线的两端抽头连接分析模块。 当应用该电感式磨粒监测装置 对油液进行检测时， 待测油液流过绝缘管。 当待测油液中的磨损微粒通过测量 单元时， 将改变测量单元的电感量， 铁磁性磨损微粒使得测量单元的电感量增 加， 而非铁磁性磨损微粒使得测量单元的电感量降低， 分析模块通过对测量单 元电感量的检测， 即可对油液中的磨损微粒进行定性和定量的检测。
理论上来说， 绝缘管的壁厚越小或待测油液的流道越窄， 则流经的磨损微 粒与测量单元的距离越近， 检测灵敏度越高。 然而由于受到管材强度和制造工 艺的限制， 绝缘管的壁厚使得绝缘管与待测磨损微粒之间始终存在较大距离， 进而使得现有技术提供的电感式磨粒监测装置的灵敏度低， 不易实现对直径在
200微米以下的磨损微粒的监测。 发明内容
本发明实施例的目的在于提供一种电感式磨粒监测装置， 以解决现有技术 提供的电感式磨粒监测装置由于测量单元中绝缘管的壁厚， 使得绝缘管与待测 磨损微粒之间存在较大距离， 灵敏度低的问题。
本发明实施例是这样实现的， 一种电感式磨粒监测装置， 所述装置包括检 测线圈以及分析模块， 所述测量单元包括：
绝缘导线， 所述绝缘导线的两端抽头连接所述分析模块；
供待测液体流过的腔体， 所述绝缘导线以螺旋状固定于所述腔体的内壁上。 上述装置中， 所述腔体的内壁设有呈螺旋状排布的一端凹槽， 所述绝缘导 线固定于所述凹槽内。
上述装置中， 所述腔体可以是由绝缘注模材料制成。
进一步地， 上述装置中， 所述绝缘注模材料可以是聚二甲基硅氧垸或聚 甲基丙烯酸甲酯。
本发明还提供了一种电感式磨粒监测装置的测量单元， 所述测量单元包括: 绝缘导线， 所述绝缘导线的两端抽头连接分析模块；
供待测液体流过的腔体， 所述绝缘导线以螺旋状固定于所述腔体的内壁上。 上述测量单元中， 所述腔体的内壁设有呈螺旋状排布的一端凹槽， 所述绝 缘导线固定于所述凹槽内。
上述测量单元中， 所述腔体可以是由绝缘注模材料制成。
上述测量单元中， 所述绝缘注模材料可以是聚二甲基硅氧垸或聚甲基丙烯 酸甲酯。
本发明还提供了一种如上所述的电感式磨粒监测装置的测量单元的制作方 法， 所述方法包括以下步骤：
将缠绕有绝缘导线的细轴固定于一模具内；
向所述模具注入液态绝缘注模材料， 并将所述模具内液态绝缘注模材料固 化成型；
将所述模具以及细轴与固化成型后的所述绝缘注模材料分离， 所述绝缘导 线以原状固定于所述绝缘注模材料内壁上。
上述方法中， 所述绝缘注模材料可以是聚二甲基硅氧垸或聚甲基丙烯酸甲 酯。
当应用本发明提供的电感式磨粒监测装置对油液或其它待测液体中的磨损 微粒进行监测时， 腔体作为待测液体的流道， 此时， 由于待测液体与绝缘导线 直接接触， 其间的理论间距为 0。 与现有技术提供的电感式磨粒监测装置相比， 待测液体中的磨损微粒能被更多的磁力线通过， 绝缘导线的电感量变化更大， 从而极大地提高了监测的灵敏度， 而且能够检测出待测液体中直径在 50微米以 下的磨损微粒， 对机器设备的安全可靠运营和人身安全有着重要意义。 附图说明
图 1是现有技术提供的电感式磨粒监测装置的原理图；
图 2是本发明提供的电感式磨粒监测装置的原理图；
图 3是本发明提供的电感式磨粒监测装置中测量单元的制作方法流程图。 图 4 是应用本发明提供的电感式磨粒监测装置检测 70微米以下磨损微粒 时， 磨损微粒直径与绝缘导线电感变化量的关系图。
具体实施方式
为了使本发明的目的、 技术方案及优点更加清楚明白， 以下结合附图及实 施例， 对本发明进行进一步详细说明。 应当理解， 此处所描述的具体实施例仅 仅用以解释本发明， 并不用于限定本发明。
图 2 示出了是本发明提供的电感式磨粒监测装置的原理， 为了便于说明， 仅示出了与本发明相关的部分。
本发明提供的电感式磨粒监测装置包括测量单元以及分析模块 13， 其中的 测量单元进一步包括： 绝缘导线， 该绝缘导线的两端抽头连接分析模块 13; 供 待测液体流过的腔体 12， 绝缘导线以螺旋状固定于腔体 12的内壁上。 具体地， 腔体 12的内壁设有呈螺旋状排布的一段凹槽 11， 绝缘导线固定于凹槽 11内。
当应用本发明提供的电感式磨粒监测装置对油液或其它待测液体中的磨损 微粒进行监测时， 腔体 12作为待测液体的流道， 此时， 由于待测液体与绝缘导 线直接接触，其间的理论间距为 0。与现有技术提供的电感式磨粒监测装置相比， 待测液体中的磨损微粒能被更多的磁力线通过， 绝缘导线的电感量变化更大， 从而极大地提高了监测的灵敏度， 而且能够检测出待测液体中微米级磨损微粒， 对机器设备的安全可靠运营和人身安全有着重要意义。
其中，腔体 12可以是由聚二甲基硅氧垸（PDMS )或聚甲基丙烯酸甲酯（PMMA) 制成， 当然， 还可以是由现有其它的绝缘注模材料制成； 其中的待测液体优选 为润滑油。 本发明还提供了一种如上所述的电感式磨粒监测装置的测量单元。 图 3是本发明提供的电感式磨粒监测装置中测量单元的制作方法流程。 在步骤 S101中， 将缠绕有绝缘导线的细轴固定于一模具内， 该细轴的直径 取决于所设计的待测液体的流道直径。
在步骤 S102中， 向该模具注入液态绝缘注模材料， 并通过加热等方式， 将 模具内液态绝缘注模材料固化成型。 其中的液态绝缘注模材料优选为聚二甲基 硅氧垸 （PDMS ) 或聚甲基丙烯酸甲酯 （PMMA)。
在步骤 S103中，将模具以及细轴与固化成型后的绝缘注模材料分离，此时， 原缠绕在细轴上的绝缘导线将仍以原状固定于绝缘注模材料内壁上， 该绝缘导 线之间的部分成为待测液体的流道。
图 4 示出了应用本发明提供的上述电感式磨粒监测装置检测 70微米以下磨 损微粒时， 磨损微粒直径与绝缘导线电感变化量的关系。
当应用本发明提供的电感式磨粒监测装置对油液或其它待测液体中的磨损 微粒进行监测时， 腔体 12作为待测液体的流道， 此时， 由于待测液体与绝缘导 线直接接触，其间的理论间距为 0。与现有技术提供的电感式磨粒监测装置相比， 待测液体中的磨损微粒能被更多的磁力线通过， 绝缘导线的电感量变化更大， 从而极大地提高了监测的灵敏度， 而且能够检测出待测液体中直径在 50微米以 下的磨损微粒， 对机器设备的安全可靠运营和人身安全有着重要意义。
以上所述， 仅为本发明较佳的具体实施方式， 但本发明的保护范围并不局 限于此， 任何熟悉本技术领域的技术人员在本发明揭露的技术范围内， 根据本 发明的技术方案及其发明构思加以等同替换或改变， 都应涵盖在本发明的保护 范围之内。

Claims

权 利 要 求 书
1、 一种电感式磨粒监测装置， 其特征在于， 所述装置包括测量单元以及 分析模块， 所述测量单元包括：
绝缘导线， 所述绝缘导线的两端抽头连接所述分析模块；
供待测液体流过的腔体， 所述绝缘导线以螺旋状固定于所述腔体的内壁上。
2、 如权利要求 1所述的电感式磨粒监测装置， 其特征在于， 所述腔体的 内壁设有呈螺旋状排布的一端凹槽， 所述绝缘导线固定于所述凹槽内。
3、 如权利要求 1所述的电感式磨粒监测装置， 其特征在于， 所述腔体是 由绝缘注模材料制成。
4、 如权利要求 3所述的电感式磨粒监测装置， 其特征在于， 所述绝缘注 模材料是聚二甲基硅氧垸或聚甲基丙烯酸甲酯。
5、 一种电感式磨粒监测装置的测量单元， 其特征在于， 所述测量单元包 括：
绝缘导线， 所述绝缘导线的两端抽头连接分析模块；
供待测液体流过的腔体， 所述绝缘导线以螺旋状固定于所述腔体的内壁上。
6、 如权利要求 5所述的电感式磨粒监测装置的测量单元， 其特征在于， 所述腔体的内壁设有呈螺旋状排布的一端凹槽， 所述绝缘导线固定于所述凹槽 内。
7、 如权利要求 4所述的电感式磨粒监测装置的测量单元， 其特征在于， 所述腔体是由绝缘注模材料制成。
8、 如权利要求 5所述的电感式磨粒监测装置的测量单元， 其特征在于， 所述绝缘注模材料是聚二甲基硅氧垸或聚甲基丙烯酸甲酯。
9、 一种如权利要求 5至 8任一项所述的电感式磨粒监测装置的测量单元 的制作方法， 其特征在于， 所述方法包括以下步骤：
将缠绕有绝缘导线的细轴固定于一模具内；
向所述模具注入液态绝缘注模材料， 并将所述模具内液态绝缘注模材料固 化成型；
将所述模具以及细轴与固化成型后的所述绝缘注模材料分离， 所述绝缘导 线以原状固定于所述绝缘注模材料内壁上。
10、 如权利要求 7所述的电感式磨粒监测装置的测量单元的制作方法， 其 特征在于， 所述绝缘注模材料是聚二甲基硅氧垸或聚甲基丙烯酸甲酯。
PCT/CN2011/074755 2011-05-27 2011-05-27 一种电感式磨粒监测装置及其测量单元 WO2012162869A1 (zh)

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