DEVELOPMENT OF SENSORS FOR MONITORING WEAR FAILURE

Optimum Instruments（客户）是数据采集领域国际公认的领导者（其客户：Suncor和Verizon）。Optimum Instruments正在开发能够真实的实时检测任何流体中的微观金属颗粒的传感器模块。颗粒的存在既是机械系统和机器内磨损的标志又是其促进因素（例如，发动机、管道、钻头）。最终，磨损会导致机器性能下降，从而增加运营和维护成本。 在这个项目中，我们研究了钻井作业中使用的发动机的磨损失效。这是由客户与位于艾伯塔省的钻井公司Precision Drilling进行的可行性研究推动的。我们将从颗粒的角度研究磨损，因为这是我们将用传感器测量的。从根本上说，我们的目标是了解颗粒是如何形成和演变的结果，在发动机中的各种磨损过程。我们希望将颗粒演变与磨损率联系起来，最终目标是通过设计涂层或促进颗粒失效的操作过程来控制颗粒尺寸、形状和颗粒数量。减少磨损将为我们的客户带来更好的经济效益，最重要的是，提供机器故障的实时监控，这将减少我们对环境的整体影响。

Optimum Instruments (the client) is an internationally recognized leader in the field of data acquisition (their clients: Suncor and Verizon). Optimum Instruments is developing sensor modules capable of detecting microscopic metallic particulates in any fluid, in real time. The presence of the particulates is both a signature and a promoter of wear within mechanical systems and machines (e.g., engines, pipes, drills). Ultimately, wear leads to a reduction in the performance of the machines, resulting in increased operational and maintenance costs. In this project, we study the wear failure of engines used in drilling operations. This is motivated by feasibility studies by the client with Precision Drilling, an Alberta-based drilling company. We will study wear from the view point of the particulate, as this is what we will measure with the sensors. Fundamentally, our objective is to understand how particulates are formed and evolve as consequence of various wear processes in the engines. We want to link particulate evolution to wear rates, with ultimate goal of controlling particulate size, shape and number of particulates through the design coatings or operating processes that promote particle failure. The reduction of wear will lead to improved economic benefits for our client and, most importantly, provide real-time monitoring of machine failure that will reduce our overall impact on the environment.