Wear-debris detection and analysis techniques for lubricant-based condition monitoring

Gravity-based focusing and size-dependent separation of metal microparticles in lubricating oil

The separation of wear microparticles in lubricating oil is crucial for improving the accuracy and throughput of the subsequent detection. However, there are few kinds of research on the separation of high-density metallic microparticles in high-viscosity lubricating oil. In this paper, a passive method for separating the metallic microparticles in oil is proposed. Gravity sedimentation was adopted to realize three-dimensional (3D) focusing of the particle by using an inclined capillary. The gravity-based 3D focusing made the sheath flow no longer responsible for the particle focusing and effectively reduced the sheath flow. Then, the separation of different-sized metallic microparticles was achieved in a horizontal channel with the aid of a sheath flow based on the different driving forces. The present method solved the problem of nonsynchronous separation of the particle in comparison to the traditional methods. This device has a simple structure with high separation efficiency, and it is easy to integrate with the detection channel. The influence of numerous parameters on the gravity-based focusing and separation was systematically studied by the numerical simulation and the experiment. The design criteria were established, which is useful in designing and employing the device, expanding its application to other non-neutral buoyancy particle separation cases, and opening up more prospects for microfluidic technology.

Microfluidic Airborne Metal Particle Sensor Using Oil Microcirculation for Real-Time and Continuous Monitoring of Metal Particle Emission

Airborne metal particles (MPs; particle size > 10 μm) in workplaces result in a loss in production yield if not detected in time. The demand for compact and cost-efficient MP sensors to monitor airborne MP generation is increasing. However, contemporary instruments and laboratory-grade sensors exhibit certain limitations in real-time and on-site monitoring of airborne MPs. This paper presents a microfluidic MP detection chip to address these limitations. By combining the proposed system with microcirculation-based particle-to-liquid collection and a capacitive sensing method, the continuous detection of airborne MPs can be achieved. A few microfabrication processes were realized, resulting in a compact system, which can be easily replaced after contamination with a low-priced microfluidic chip. In our experiments, the frequency-dependent capacitive changes were characterized using MP (aluminum) samples (sizes ranging from 10 μm to 40 μm). Performance evaluation of the proposed system under test-bed conditions indicated that it is capable of real-time and continuous monitoring of airborne MPs (minimum size 10 μm) under an optimal frequency, with superior sensitivity and responsivity. Therefore, the proposed system can be used as an on-site MP sensor for unexpected airborne MP generation in precise manufacturing facilities where metal sources are used.

Multifunctional Detection Sensor and Sensitivity Improvement of a Double Solenoid Coil Sensor

A multifunction detection sensor for hydraulic oil contaminants based on a microfluidic chip is proposed, which consists of double solenoid coils and a straight microchannel. The inductance detection model of metal particles and capacitance detection model of nonmetal particles are constructed theoretically. In order to further improve detection sensitivity, experiments of effects of silicon steel sheets on the sensitivity of detection are carried out. Experimental results show that the silicon steel sheets can significantly improve the detection sensitivity of metal particles. The inductance amplitude and signal-to-noise (SNR) of iron particles ranging from 60-130 μm and copper particles ranging from 120-180 μm can be increased by at least 7.0-2.4 and 4.5-2.0 times, respectively. We demonstrate the successful detection of 30 μm iron particles and 90 μm copper particles using double solenoid coils with silicon steel sheets. In capacitance detection experiments, the silicon steel sheets can improve the sensitivity of capacitance detection, but the improvement effect is not obvious. We demonstrate the successful detection of 140 μm water droplets and 240 μm bubbles using double solenoid coils with and without silicon steel sheets. The capacitance amplitude and SNR of detecting water droplets ranging from 140-150 μm and bubbles ranging from 240-250 μm can be increased by 37.4-21.9% and 18.5-8.0% using double solenoid coils with silicon steel sheets, respectively.

Performance Analysis of Retrofitted Tribo-Corrosion Test Rig for Monitoring In Situ Oil Conditions

Oils and lubricants, once extracted after use from a mechanical system, can hardly be reused, and should be refurbished or replaced in most applications. New methods of in situ oil and lubricant efficiency monitoring systems have been introduced for a wide variety of mechanical systems, such as automobiles, aerospace aircrafts, ships, offshore wind turbines, and deep sea oil drilling rigs. These methods utilize electronic sensors to monitor the "byproduct effects" in a mechanical system that are not indicative of the actual remaining lifecycle and reliability of the oils. A reliable oil monitoring system should be able to monitor the wear rate and the corrosion rate of the tribo-pairs due to the inclusion of contaminants. The current study addresses this technological gap, and presents a novel design of a tribo-corrosion test rig for oils used in a dynamic system. A pin-on-disk tribometer test rig retrofitted with a three electrode-potentiostat corrosion monitoring system was used to analyze the corrosion and wear rate of a steel tribo-pair in industrial grade transmission oil. The effectiveness of the retrofitted test rig was analyzed by introducing various concentrations of contaminants in an oil medium that usually leads to a corrosive working environment. The results indicate that the retrofitted test rig can effectively monitor the in situ tribological performance of the oil in a controlled dynamic corrosive environment. It is a useful method to understand the wear-corrosion synergies for further experimental work, and to develop accurate predictive lifecycle assessment and prognostic models. The application of this system is expected to have economic benefits and help reduce the ecological oil waste footprint.

A microfluidic Coulter counting device for metal wear detection in lubrication oil

We present the design, fabrication, and testing of a microfluidic device for metal wear detection in lubrication oils. The detection is based on the capacitance Coulter counting principle, that is, on the change in a microchannel's capacitance caused by the presence of a metal particle in the microchannel. The testing of the microfluidic device using 10-25 microm aluminum particles has demonstrated the feasibility for detection and counting of microscale metal particles in low-conductive lubrication oils. This microfluidic device is promising for online oil debris detection by the use of multiple detection microfluidic channels.