SBIR Phase I: Development of Integrated Oil Debris Sensors for Machinery Fault Detection and Conditioning Monitoring

这项小企业创新研究（SBIR）第一阶段项目旨在通过检测机械中的金属和非金属磨损碎片，开发一种创新的集成磨损碎片传感器，用于旋转和往复式机械的状态健康监测。S润滑油。今天好吗?大多数在线碎片传感器只能提供有限的机器磨损进展信息，或者不具备现场在线功能。这个第一阶段的项目将专注于建立一个实验室原型，以演示概念验证的高通量检测、区分、表征和计数，非金属和金属（黑色金属和有色金属）碎片的范围从20ìm到150ìm(这是机器的指示？磨损状态)实时。集成传感器将包括1)具有独特流槽设计的超声波传感单元，可准确检测所有金属和非金属碎片，以及2)检测和区分黑色金属和有色金属碎片的电感库尔特计数传感单元。预计该传感器能够准确测量各种类型磨损碎片的大小和浓度，从而为各种高速旋转机械（包括旋翼飞机变速器和涡轮轴发动机）的调节维护和寿命预测提供信息。该项目具有更广泛的影响和商业潜力，是一种创新的高通量油屑传感技术，可提供突发灾难性故障的预警，促进更好的维护计划，并显着降低机器运行成本。该传感器的高通量和高灵敏度，以及其低成本和紧凑的尺寸，使其成为各种机械（如轴承，齿轮箱和涡轮机械）的实时状态监测和寿命预测的理想仪器，从而对运输，制造和军事工业具有更广泛的影响和商业潜力。它是现有的离线油磨损碎片分析的有力补充。所提出的研究将为开发用于微/纳米级粒子传感的先进传感器系统奠定科学基础。特别是，在非导电、高粘性环境中的粒子传感研究，将对监测涉及微/纳米颗粒的新型软材料加工，以及在非导电材料和环境中检测金属和介电颗粒污染的传感器的发展产生变革性影响。

This Small Business Innovation Research (SBIR) Phase I project aims to develop an innovative integrated wear debris sensor for condition health monitoring of rotating and reciprocating machinery via detecting metallic and nonmetallic wear debris in the machinery?s lubrication oil. Today?s online debris sensors can provide only limited information on the progression of machine wear or do not have in-situ online capability. This Phase I project will focus on building a laboratory prototype to demonstrate the proof-of-concept high-throughput detection, differentiation, characterization, and counting of nonmetallic, and metallic (ferrous and non-ferrous) debris ranging from 20ìm to 150ìm (which are indicative of machines? wear status) in real time. The integrated sensor will consist of 1) an ultrasonic sensing unit with a unique flow recess design that accurately detects all metallic and non-metallic debris, and 2) an inductive Coulter counting sensing unit that detects and differentiates ferrous and non-ferrous metallic debris. It is anticipated this sensor is able to accurately measure wear debris size and concentration of each type, and thus provide information for conditioning based maintenance and life prognosis of a variety of high speed rotary machinery including rotorcraft transmissions and turboshaft engines.The broader impact/commercial potential of this project is an innovative high throughput oil debris sensing technology that provide advance warning of sudden catastrophic failure, facilitate better maintenance scheduling, and significantly reduce the cost of machine operation. The high throughput and high sensitivity of the sensor, along with its low cost and compact size, makes it an ideal instrument for real-time condition monitoring and life prognosis for a variety of machinery such as bearings, gearboxes, and turbomachinery, and thereby have broader impacts on and commercial potentials for the transportation, manufacturing and military industries. It is a powerful complement to existing offline oil wear debris analysis. The proposed research will form the scientific foundation for the development of advanced sensors systems for micro/nanoscale particle sensing. In particular, studies of particle sensing in a nonconductive, high viscous environment are poised to have a transformative impact on monitoring new soft materials processing involving micro/nano particles, and the development of sensors for detecting metallic and dielectric particle contamination in nonconductive materials and environments.