Simulation and Experimental Study of a Triple-Coils Wear Debris Inductance Sensor

Simulation optimization and experimental study of a triple-coils inductive oil wear debris sensor to achieve effective monitoring of wear debris. To address the problems of low monitoring sensitivity and high false alarm rate in the practical application of metal chip end sensors, firstly, a mathematical model of the output induced electric potential is established based on the detection principle of three-coil inductive sensors. Secondly, a simulation model is constructed based on the influencing factors in the mathematical model to provide a basis for optimizing the coil structure. Finally, the inductive sensor is fabricated according to the actual oil flow pipe diameter and flow rate, and an experimental platform is built in the laboratory environment for testing. The output sensing signal is demodulated using an envelope detector algorithm, and an outlier point detection method based on the “3sigma” rule is used to identify abrasive debris. Experimental results have demonstrated that the triple-coils inductive oil wear debris sensor achieves the identification of 2mm abrasive particles within the constraints of the oil line diameter.