CN100365413C - Short deposition distance image type online ferrography device and method - Google Patents
Short deposition distance image type online ferrography device and method Download PDFInfo
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- CN100365413C CN100365413C CNB200610041773XA CN200610041773A CN100365413C CN 100365413 C CN100365413 C CN 100365413C CN B200610041773X A CNB200610041773X A CN B200610041773XA CN 200610041773 A CN200610041773 A CN 200610041773A CN 100365413 C CN100365413 C CN 100365413C
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- 238000000034 method Methods 0.000 title claims abstract description 21
- 239000002245 particle Substances 0.000 claims abstract description 66
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 78
- 229910052742 iron Inorganic materials 0.000 claims description 37
- 230000003595 spectral effect Effects 0.000 claims description 31
- 239000012530 fluid Substances 0.000 claims description 16
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- 239000006061 abrasive grain Substances 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
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- 229910001369 Brass Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
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- 230000005540 biological transmission Effects 0.000 description 1
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Abstract
本发明公开了一种短沉积距离图像型在线铁谱装置与方法，短沉积距离图像型在线铁谱装置，计算机通过D/A卡与功放相连，功放的一个输出通道与铁谱传感器的线圈相连并为其提供励磁电流，功放的另一个通道与油泵相接，通过计算机控制功放的输出电压调节工作磁场强度和油液流量，铁谱传感器通过USB接口与计算机相连。用计算机控制磁场和流量的变化，在同一测量区域实现不同尺寸磨粒的沉积方法。实现采集区域内大、小磨损磨粒的分别沉积，减小了磨粒在工作气隙上方的沉积距离，只需要一个图像传感器就可以实现磨粒图像采集，自动得到磨粒的粒度分布、浓度和形貌信息，体积小、自动化程度高，易于操作，适合工业现场使用。
The invention discloses a short deposition distance image type online ferrography device and method. The short deposition distance image type online ferrography device, the computer is connected with the power amplifier through the D/A card, and an output channel of the power amplifier is connected with the coil of the ferrography sensor And provide excitation current for it, the other channel of the power amplifier is connected with the oil pump, the output voltage of the power amplifier is controlled by the computer to adjust the working magnetic field strength and the oil flow, and the ferrographic sensor is connected to the computer through the USB interface. The change of magnetic field and flow is controlled by computer, and the deposition method of abrasive particles of different sizes can be realized in the same measurement area. Realize the separate deposition of large and small wear abrasive particles in the collection area, which reduces the deposition distance of abrasive particles above the working air gap. Only one image sensor is needed to realize image acquisition of abrasive particles, and the particle size distribution and concentration of abrasive particles can be obtained automatically And shape information, small size, high degree of automation, easy to operate, suitable for industrial field use.
Description
Technical field
The present invention relates to equipment attrition particle monitoring apparatus and method, particularly a kind of short deposition distance image on-line iron spectral apparatus and method.
Background technology
Existing ferrous specturm technique is to utilize high strength and high-gradient magnetic field from fluid the ferromagnetism abrasive particle to be separated, and makes them realize deposition, a kind of technology that it is analyzed and studies then in order according to size.Ferrous specturm technique monitoring grit size wider range, can understand the abrasion mechanism and the abrading section of equipment by observing the abrasive particle shape characteristic, and utilize wear particle concentration and size-grade distribution to judge the overall wear level of machine, be a kind of effective ways that carry out equipment Life cycle status monitoring and residual life estimation.
Ferrous specturm technique comprises two kinds of off-line ferrous specturm technique and on-line ferrograph technology.The collection of abrasive particle is realized in the magnetic field that the off-line ferrous specturm technique utilizes permanent magnet to produce, and according to granule size abrasive particle is deposited on spectrum sheet or the deposited tube in order.By a plurality of wear particle depositions district is carried out photo densitometry, can directly calculate the wear particle concentration and the size-grade distribution of fluid, be referred to as direct-reading off-line iron spectrum.If carry out the observation and the analysis of abrasive particle pattern by means of iron spectrum microscope, then be referred to as analysis mode off-line iron spectrum.Owing to be a kind of technology of non-online use, can only carry out periodic sampling to monitored equipment, operating process needs manual intervention, and is more consuming time, and the equipment price costliness, also higher to operator's experience requirement.The on-line ferrograph technology produces the on-line automatic wear particle deposition that carries out of controllable magnetic field by electromagnet, do not need fluid is diluted, saved the manual intervention link of off-line iron spectrum, can realize intensive sampling, improve the probability that obtains the fault signature abrasive particle, eliminated the artifical influence factor in the off-line method operating process.
90223714.4) and " on-line monitoring ferrograph " (patent No.: 01240347.4) Xi'an Communications University obtains the patent of two on-line ferrograph technical elements respectively in nineteen ninety and calendar year 2001, be respectively " the online ferrograph of electromagnetism photoelectricity " (patent No.:.In last patent, adopt photoelectric sensor to detect abrasive particle shading area, reflect the quantity of different grain size abrasive particle, but can not obtain the image information of abrasive particle with this; Adopt in the patent in back and last the identical electromagnet apparatus of patent, difference is that the information that will deposit abrasive particle by image-carrying fiber bundle is delivered on the cmos image sensor, not only can measure the concentration information of abrasive particle, and can obtain image information, but the abrasive particle in only detecting among a small circle, the software and hardware system complexity is installed and used difficulty.2005, Xi'an Communications University has applied for " online digital image electromagnetic permanent-magnet mixed field spectrum sensor " patent of invention (patent publication No.: CN 1673733A), a kind of online digital image electromagnetic permanent-magnet mixed field spectrum sensor is disclosed, use by composite excitation mode and cmos image sensor, can reduce the volume and the power consumption of on-line ferrograph sensor greatly, and the iron spectrogram that can obtain wear debris in real time is as information.
Fluid is all along flowing perpendicular to magnetic induction density direction in the working gas gap in above-mentioned three patents, during the deposition abrasive particle, excitation intensity is constant, under the combined action that magnetic field force, gravity, buoyancy and fluid flow, abrasive particle realizes disperseing deposition in order according to granule size on whole magnetic pole length direction, rely on oily flow path direction and arrange that a plurality of senser elements carry out the detection of different grain size abrasive particle, need magnetic pole to have long length, thereby limited reducing of sensor bulk.Aspect the light source of imaging, only used the transmitted light source pattern, carry out can not reflecting when Debris Image is gathered the shape characteristic on abrasive particle surface.
Summary of the invention
For addressing the above problem, the present invention proposes a kind of short deposition distance image on-line iron spectral apparatus and method, wherein oily flow path direction is parallel to magnetic induction density direction in the working gas gap in the iron spectral sensor, magnetic field intensity and flow by the online adjusting iron spectral sensor of computing machine, realize in the pickup area big, the deposition respectively of little wear debris, replaced the past excitation parameter to fix, deposit the method for different abrasive particles by the locus of selecting suitable magnetic induction density, reduced the deposition distance of abrasive particle above working gas gap, only need an imageing sensor just can realize the Debris Image collection, automatically obtain the size-grade distribution of abrasive particle, concentration and pattern information, volume is little, the automaticity height, easy operating is fit to industry spot and uses.
Technical scheme of the present invention is achieved in that
The short deposition distance image on-line iron spectral device, comprise computing machine, D/A card, power amplifier and oil pump, computing machine links to each other with power amplifier by the D/A card, an output channel of power amplifier links to each other with the coil of iron spectral sensor and provides exciting current for it, another passage and the oil pump of power amplifier join, by the output voltage adjusting work magnetic field intensity and the fluid flow of computer control power amplifier, iron spectral sensor links to each other with computing machine by USB interface.
Runner is set in the iron spectral sensor, and the fluid flow direction is parallel to the direction of the magnetic induction density that magnetic pole produces in the runner in working gas gap, and oil pocket is set in the runner, and the oil pocket width is 3～7 times of oil pocket height.
The upper bottom surface top of runner is equipped with reflection source.
The short deposition distance image on-line iron spectral method, the computerized control variation of magnetic field and flow, realize the deposition process of different size abrasive particle in same measured zone: abrasive type that at first need to select collection: then, gather if desired and be of a size of 20 microns～100 microns big abrasive particle, the computer control iron spectral sensor is operated in 200 ampere-turns～800 ampere-turn low-intensity magnetic fields states, oil pump is pumped at a high speed with the flow of 2ml/min～10ml/min, fluid extracts and finishes, oil pump stops oil pumping, and imageing sensor is of a size of the image acquisition of 20 microns～100 microns big abrasive particle; Gather if desired and be of a size of 5 microns～20 microns little abrasive particle, iron spectral sensor is operated in 1000 ampere-turns～1600 ampere-turn high-intensity magnetic field states, oil pump is with the flow low speed oil pumping of 0.1ml/min～2ml/min, oil sample extracts and finishes, oil pump stops oil pumping, and imageing sensor is of a size of the image acquisition of 5 microns～20 microns little abrasive particle; At last, the Debris Image of gathering is sent to carries out data analysis in the computing machine; If continue to gather, then turn back to and gather the abrasive type selection, otherwise finish.
The on-line ferrograph device that the present invention relates to, iron spectral sensor has only the surveyed area of a deposition abrasive particle, this zone possesses reflection source and transmitted light source, by the control of computing machine to magnetic field and flow, by the use of single cmos image sensor, just can realize the online real time collecting of large and small grain size abrasive grain image, obtain size-grade distribution, concentration and the pattern information of abrasive particle, promptly have the function of analysis mode iron spectrum and direct-reading iron spectrum simultaneously, and reduced the volume of on-line ferrograph sensor.
Description of drawings
Fig. 1 is a schematic diagram of the present invention;
Fig. 2 is a workflow diagram of the present invention;
Fig. 3 is an iron spectral sensor structural representation of the present invention;
Fig. 4 is the wiring layout of picture signal collecting part of the present invention and runner;
Fig. 5 is a flow passage structure synoptic diagram of the present invention.
Specific embodiment
Accompanying drawing is specific embodiments of the invention;
Below in conjunction with accompanying drawing content of the present invention is described in further detail:
With reference to shown in Figure 1, the structural principle and the principle of work of apparatus of the present invention are: the present invention includes computing machine 1, D/A card 2, power amplifier 3 and oil pump 4, computing machine 1 is by the output of D/A card 2 control power amplifiers 3, power amplifier 3 links to each other with iron spectral sensor 5, carry out excitation and light source control, simultaneously, computing machine 1 joins with oil pump 4 by D/A card 2 and power amplifier 3, carries out the flow control of oil pump 4.Like this under the control of computing machine 1, by regulating work magnetic field intensity and fluid flow, realize the respectively deposition of large and small abrasive particle, replaced the past excitation parameter to fix, deposit the method for different abrasive particles by the locus of selecting suitable magnetic induction density at the same area.When oil sample to be measured enters iron spectral sensor 5 under the effect of oil pump 4, carry out the abrasive particle collection, and on-line ferrograph image output is sent in the computing machine 1 by USB port analyzes.
With reference to shown in Figure 2, the workflow of the inventive method is: abrasive type that at first need to select collection: gather if desired and be of a size of 20 microns～100 microns big abrasive particle, computing machine 1 control iron spectral sensor 5 is operated in 200 ampere-turns～800 ampere-turn low-intensity magnetic fields states, oil pump 4 is pumped at a high speed with the flow of 2ml/min～10ml/min, under this condition, have only big abrasive particle to deposit, wait to reach the sampling quantity of setting, oil pump 4 stops oil pumping, carries out the image acquisition of big abrasive particle; Gather if desired and be of a size of 5 microns～20 microns little abrasive particle, iron spectral sensor 5 is operated in 1000 ampere-turns～1600 ampere-turn high-intensity magnetic field states, oil pump 4 is with the flow low speed oil pumping of 0.1ml/min～2ml/min, under little abrasive particle can deposit under this condition, wait to reach the sampling quantity of setting, oil pump 4 stops oil pumping, carries out the image acquisition of little abrasive particle; The Debris Image that collects is sent to carries out data analysis in the computing machine 1,, then turn back to and gather abrasive type and select, otherwise finish if continue to gather.
With reference to shown in Figure 3, iron spectral sensor of the present invention comprises iron core 6, coil 7 and magnetic pole 8, and wherein coil 7 is enclosed within on unshakable in one's determination 6, and magnetic pole 8 is fixed on unshakable in one's determination 6, magnetic pole 8 tops are equipped with runner 15, and oily flow path direction is parallel to the direction of magnetic induction density in the working gas gap in the runner 15; Be fixed with camera lens 14 on the runner 15, camera lens 14 links to each other with cmos image sensor 19, and cmos image sensor 19 is fixed on the circuit board 11, has usb data transmit port 12 to link to each other with computing machine 1 on the circuit board 11; In the middle of the magnetic pole 8 working gas gap is arranged, leaded light glass 16 is installed in the working gas gap, and the lower surface of leaded light glass 16 is connected with transmitted light source 17.
When carrying out the abrasive particle collection, iron core 6, coil 7 and the magnetic pole 8 common the action of a magnetic fields that produce are in oil pocket 27, the fluid flow direction is parallel to the direction of magnetic induction density in the working gas gap, the magnetic field of working gas gap upper area deposition abrasive particle is the strongest in the oil pocket 27, so after fluid enters runner oil pocket 27 from pipe adapter 10, abrasive particle mainly deposits in this regional short distance, carry out image acquisition by 19 pairs of depositions of cmos image sensor abrasive particle, through the usb data transmit port 12 on the circuit board 11 Debris Image is sent in the computing machine 1 and analyzes.Under the control of computing machine 1, by exciting current in the regulating winding 7 and oil pump 4 flows, can realize the deposition respectively of large and small grain size abrasive grain in this wear particle deposition district, so above working gas gap, only need to install the collection that a cmos image sensor 19 just can be realized big or small Debris Image, reduce the length of magnetic pole 8 greatly, thereby reduced the volume of iron spectral sensor 5.Owing to adopt the mode of electromagnetism excitation, after image acquisition finished, the magnetic field of will working reduced to zero, carried out depositing washing away of abrasive particle in the runner 15, for next abrasive particle collection is prepared, realized the deposition repeatedly of abrasive particle.
Transmitted light source 17 adopts flat-plate luminous diode array, meets the spectral response range of cmos image sensor 19, has that light distribution is even, easy for installation, high reliability features.Leaded light glass 16 adopts optical glass to make, and is embedded in the working gas gap, has not only played the effect for cmos image sensor 19 conduction transmitted lights, but also can prevent that pollutant from entering the Debris Image acquisition zone.
With reference to shown in Figure 4, a groove 26 has been opened at the middle part of runner 15, embeds bottom surface 18, has opened a groove 24 on the bottom surface of groove 26 again, embeds upper bottom surface 21, and last bottom surface mutual group becomes the oil pocket 27 of runner 15; Camera lens 14 is fixed on the top of upper bottom surface 21 by being threaded, and links to each other with cmos image sensor 19, and cmos image sensor 19 is fixed on the circuit board 11, and usb data transmit port 12 is arranged on the circuit board 11; The two ends of runner 15 have two through holes 25, attachment screw 9 is installed is used for realizing being connected and fixed of runner 15, magnetic pole 8 and iron core 6; Have hole 22 in the inboard of through hole 25, mounting pipe joint 10; In the inboard of connecting hole 22, opened two holes 23 again, be used for the installation of reflection source 20 power leads.
On upper bottom surface 21, be pasted with two reflection sources 20, carrying out Debris Image when gathering, can cremasteric reflex light, so just can observe the surface appearance feature of abrasive particle.Consider that installing space is very limited, reflection source 20 can adopt the light emitting diode of SMD packing forms.
Runner 15 adopts non-magnetic materials processing to form, and in order to guarantee to have certain strength of joint, can adopt brass to come processing and fabricating runner 15.Upper bottom surface 21 and bottom surface 18 adopt the optical glass of high transmission rate to make, and are beneficial to transmitted light source 17 and the reflection source 20 effects collection of 19 pairs of Debris Image of cmos image sensor down.Undertaken bondingly between last bottom surface and the runner 15 by epoxy resin, guaranteed that oil pocket 27 has good sealing property.
With reference to shown in Figure 5, a groove has been opened at the middle part of runner 15, embeds bottom surface 18, and a groove 24 has been arranged out on the bottom surface of groove 26, embeds upper bottom surface 21, and last bottom surface mutual group becomes the oil pocket 27 of runner 15; Upper bottom surface 21 is equipped with reflection source 20; The two ends of runner 15 have two through holes 25, attachment screw 9 is installed is used for realizing being connected and fixed of runner 15, magnetic pole 8 and iron core 6; Have hole 22 in the inboard of through hole 25, mounting pipe joint 10; In the inboard of connecting hole 22, opened two holes 23 again, be used for the installation of reflection source 20 power leads.
Whole device carries out work under the control of computing machine 1, computing machine is by the output of D/A card 2 control power amplifiers 3, the working flow of exciting current in the regulating winding 7 and oil pump 4 on the one hand; On the other hand, under the control of computing machine 1, each parts are according to above-mentioned flow process cooperating in the device, finish the collection of abrasive particle jointly: abrasive type that at first need to select collection: gather if desired and be of a size of 20 microns～100 microns big abrasive particle, computing machine 1 control iron spectral sensor 5 is operated in 200 ampere-turns～800 ampere-turn low-intensity magnetic fields states, oil pump 4 is pumped at a high speed with the flow of 2ml/min～10ml/min, fluid extracts and finishes, oil pump 4 stops oil pumping, and the big abrasive particle that 19 pairs of imageing sensors are deposited on bottom surface 18 carries out image acquisition; Gather if desired and be of a size of 5 microns～20 microns little abrasive particle, iron spectral sensor 5 is operated in 1000 ampere-turns～1600 ampere-turn high-intensity magnetic field states, oil pump 4 is with the flow low speed oil pumping of 0.1ml/min～2ml/min, oil sample extracts and finishes, oil pump 4 stops oil pumping, and imageing sensor 19 carries out the image acquisition of little abrasive particle; The Debris Image that collects is sent to carries out data analysis in the computing machine 1,, then turn back to and gather abrasive type and select, otherwise finish if continue to gather.Use short deposition apart from the on-line ferrograph device according to the method described above, can realize the image acquisition of large and small abrasive particle in the fluid, can the degree of wear and the abrading section of equipment be judged, ensured safety, the reliability service of equipment effectively.
Claims (3)
1. short deposition distance image on-line iron spectral device, comprise computing machine (1), D/A card (2), power amplifier (3) and oil pump (4), it is characterized in that, computing machine (1) links to each other with power amplifier (3) by D/A card (2), an output channel of power amplifier (3) links to each other with the coil (7) of iron spectral sensor (5) and provides exciting current for it, another passage of power amplifier (3) and oil pump (4) join, by the output voltage adjusting work magnetic field intensity and the fluid flow of computing machine (1) control power amplifier (3), iron spectral sensor (5) links to each other with computing machine (1) by USB interface; Runner (15) is set in the iron spectral sensor (5), the fluid flow direction is parallel to the direction of the magnetic induction density that magnetic pole (8) produces in working gas gap in the runner (15), oil pocket (27) is set in the runner (15), and oil pocket (27) width is 3～7 times of oil pocket (27) height.
2. short deposition distance image on-line iron spectral device according to claim 1 is characterized in that, upper bottom surface (21) top of runner (15) is equipped with reflection source (20).
3. a short deposition distance image on-line iron spectral method is characterized in that, with the variation of computing machine (1) controlling magnetic field and flow, realizes the deposition process of different size abrasive particle in same measured zone: abrasive type that at first need to select collection; Then, gather if desired and be of a size of 20 microns～100 microns big abrasive particle, computing machine (1) control iron spectral sensor (5) is operated in 200 ampere-turns～800 ampere-turn low-intensity magnetic fields states, oil pump (4) is pumped at a high speed with the flow of 2ml/min～10ml/min, fluid extracts and finishes, oil pump (4) stops oil pumping, and imageing sensor (19) is of a size of the image acquisition of 20 microns～100 microns big abrasive particle; Gather if desired and be of a size of 5 microns～20 microns little abrasive particle, iron spectral sensor (5) is operated in 1000 ampere-turns～1600 ampere-turn high-intensity magnetic field states, oil pump (4) is with the flow low speed oil pumping of 0.1ml/min～2ml/min, oil sample extracts and finishes, oil pump (4) stops oil pumping, and imageing sensor (19) is of a size of the image acquisition of 5 microns～20 microns little abrasive particle; At last, the Debris Image of gathering is sent in the computing machine (1) carries out data analysis; If continue to gather, then turn back to and gather the abrasive type selection, otherwise finish.
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| CN102288524B (en) * | 2011-07-21 | 2013-11-06 | 西安交通大学 | On-line image visual ferrography stack-free concentration index monitoring method for deposited abrasive particles |
| CN102323195B (en) * | 2011-08-01 | 2013-05-22 | 西安交通大学 | On-line Image Visual Ferrography Device Deposition Parameter Experimental Setting Method |
| CN104865168A (en) * | 2014-02-26 | 2015-08-26 | 南京理工大学 | Ferrograph for ships and measurement and analysis method |
| CN103983543B (en) * | 2014-05-15 | 2017-01-04 | 西安交通大学 | A kind of online image visual ferrum spectrum imaging system |
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| CN108896448B (en) * | 2018-05-11 | 2020-10-16 | 重庆邮电大学 | On-line metal particle monitoring sensor and monitoring method based on axial high gradient magnetic field |
| CN109324034B (en) * | 2018-11-12 | 2024-10-11 | 中国计量大学 | Rolling bearing defect detection device based on oil spectrum analysis and magnetic leakage detection |
| CN110672609A (en) * | 2019-10-16 | 2020-01-10 | 广州机械科学研究院有限公司 | Automatic ferrographic analysis system based on image recognition |
| CN111282713B (en) * | 2020-02-14 | 2021-11-12 | 山东大学 | Electromagnetic device and method for ordered deposition of wear particles |
| CN115290513A (en) * | 2022-08-26 | 2022-11-04 | 江苏徐工工程机械研究院有限公司 | Abrasive particle analysis system, method and apparatus |
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| CN1811402A (en) | 2006-08-02 |
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