Deployment of an inductance-based quasi-digital sensor to detect metallic wear debris in lubricant oil of rotating machinery

In rotating machinery due to continuous rotational induced wear and tear, metallic debris will be produced and mixes with the in-service lubricant oil over the course of time. This debris gives the sign of potential machine failure due to the aging of critical parts like gears and bearings. The size and type of wear debris has a direct relationship with the degree of wear in the machine and gives information about the healthiness of equipment. This article presents an inductive quasi-digital sensor to detect the metallic debris, its type; size in the lubrication oil of rotating machinery. A microcontroller based low cost, low power, high resolution and high precise instrument with alarm indication and LCD is developed to detect ferrous debris of sizes from 30 µm and non-ferrous debris of 50 µm. It is thoroughly tested and calibrated with ferrous, non-ferrous debris of different sizes in the air environment. Finally, an experiment is conducted to check the performance of the instrument by circulating lubricant oil containing ferrous, non-ferrous debris through the sensor.