A high sensitivity wear debris sensor using ferrite cores for online oil condition monitoring

Detecting wear debris and measuring the increasing number of wear debris in lubrication oil can indicate abnormal machine wear well ahead of machine failure, and thus are indispensable for online machine health monitoring. A portable wear debris sensor with ferrite cores for online monitoring is presented. The sensor detects wear debris by measuring the inductance change of two planar coils wound around a pair of ferrite cores that make the magnetic flux denser and more uniform in the sensing channel, thereby improving the sensitivity of the sensor. Static testing results showed this wear debris sensor is capable of detecting 11 µm and 50 µm ferrous debris in 1 mm and 7 mm diameter fluidic pipes, respectively; such a high sensitivity has not been achieved before. Furthermore, a synchronized sampling method was also applied to reduce the data size and realize real-time data processing. Dynamic testing results demonstrated that the sensor is capable of detecting wear debris in real time with a high throughput of 750 ml min−1; the measured debris concentration is in good agreement with the actual concentration.

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