On the Investigation of Frequency Characteristics of a Novel Inductive Debris Sensor

Lubricants have the ability to reduce frictions, prevent wear, convey metal debris particles and increase the efficiency of heat transfer; therefore, they have been widely used in mechanical systems. To assess the safety and reliability of the machine under operational conditions, the development of inductive debris sensors for the online monitoring of debris particles in lubricants has received more attention from researchers. To achieve a high-precision, high-efficiency sensor for accurate prediction on the degree of wear, the equivalent circuit model of the sensor coil has been established, and its equations discovering the relationship between the induced voltage and excitation frequency have been derived. Furthermore, the influence of excitation frequencies and metal debris on the magnetic flux density has been analyzed throughout the simulations to determine the sensor magnetic field. In order to identify a frequency range suitable for detecting both ferrous and non-ferrous materials with a high level of sensitivity, the analytical analysis and experiments have been conducted to investigate the frequency characteristics of the developed inductive debris sensor prototype and its improved inspection capability. Moreover, the developed inductive debris sensor with the noticeable frequency characteristics has been assessed and its theoretical model has been also validated throughout experimental tests. Results have shown that the detection sensitivity of non-ferrous debris by the developed sensor increases with the excitation frequency in the range of 50 kHz to 250 kHz, while more complex results for the detection of ferrous debris have been observed. The detection sensitivity decreases as the excitation frequency increases from 50 kHz to 300 kHz, and then increases with the excitation frequency from 300 kHz to 370 kHz. This leads to the effective selection of the excitation frequency in the process of inspection. In summary, the investigation into the frequency characteristics of the proposed novel inductive debris sensor has enabled its broad applications and also provided a theoretical basis and valuable insights into the development of inductive debris sensors with improved detection sensitivity.