Improving Sensitivity of Ferrous Particle Sensors with Permanent Magnet

This study aimed to improve sensitivity of ferrous particle sensors used in various mechanical systems such as wind power gearboxes to detect abnormalities by measuring the amount of ferrous wear particles generated by metal-to-metal contact. Existing sensors collect ferrous particles using a permanent magnet. However, its ability to detect abnormalities is limited because it only measures amounts of ferrous particles collected on the top of the sensor. To overcome this limitation, this study evaluated sensibility of an existing sensor using a multi-physics analysis method and improved it by changing the core shape inside the sensor. The detection ability of the improved sensor was analytically shown to be better than the existing sensor. This study highlights the use of analytical methods and multi-physics analysis for developing a ferrous particle sensor and presents a method to compare sensibility analytically. Results of the improved sensor are expected to enhance the ability to detect abnormalities in the lubrication system where ferrous wear particles are generated. This study will contribute to the development of more effective ferrous particle sensors, which can potentially improve the performance and reliability of mechanical systems.