A CONTAMINANT SENSOR FOR DETECTING MAGNETIZABLE CONTAMINANTS IN LUBRICANT FLOW

Abstract

A contaminant sensor (1) for detecting magnetizable contaminants (7) present in a lubricant flow is disclosed. A permanent magnet (3) is arranged movably inside a sensor housing (2). A sensor element (6, 11, 13), e.g. in the form of a distance sensor (6) or a pressure sensor (11), is arranged to detect a displacement of the permanent magnet (3) inside the sensor housing (2), and an indicator is arranged to generate an alert signal when a displacement and/or a rate of change of displacement of the permanent magnet (3) inside the sensor housing (2) exceeds a pre-defined threshold value. The permanent magnet (3) is arranged to move inside the sensor housing (2) in response to magnetizable contaminants (7) collected on an outer surface of the sensor housing (2).

Claims

1. A contaminant sensor for detecting magnetizable contaminants present in a lubricant flow, the contaminant sensor comprising: a sensor housing, a permanent magnet arranged movably inside the sensor housing, a resilient member operationally coupled to the permanent magnet, a sensor element arranged to detect a displacement of the permanent magnet inside the sensor housing, an indicator arranged to generate an alert signal when a displacement and/or a rate of change of displacement of the permanent magnet inside the sensor housing exceeds a predefined threshold value, wherein the permanent magnet is arranged to move inside the sensor housing in response to magnetizable contaminants collected on an outer surface of the sensor housing.

2. The contaminant sensor according to claim 1, wherein the resilient member is or comprises a spring element and/or a bellow.

3. The contaminant sensor according to claim 1, wherein the sensor element is or comprises a distance sensor arranged to measure a distance between the distance sensor and the permanent magnet or a member attached to the permanent magnet.

4. The contaminant sensor according to claim 1, wherein the resilient member is or comprises a bellow attached to the permanent magnet, and wherein the sensor element is or comprises a pressure sensor arranged to measure a pressure inside and/or outside the bellow.

5. The contaminant sensor according to claim 1, wherein the sensor element is or comprises a force sensor arranged to measure a force exerted by the permanent magnet.

6. The contaminant sensor according to claim 1, wherein the permanent magnet is movable against a force provided by the resilient member in response to magnetizable contaminants collected on the outer surface of the sensor housing.

7. The contaminant sensor according to claim 1, wherein the sensor element is at least partly arranged inside the sensor housing.

8. A lubrication system for lubricating a wind turbine component, the lubrication system having a contaminant sensor according to claim 1 detachably mounted therein.

9. The lubrication system according to claim 8, wherein the wind turbine component is or forms part of a drive train.

10. The lubrication system according to claim 8, wherein the contaminant sensor is arranged to retain contaminants collected on an outer surface of the sensor housing, the collected contaminants thereby being removable from the lubrication system along with the detachable contaminant sensor.

11. A wind turbine comprising a lubrication system according to claim 8.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The invention will now be described in further detail with reference to the accompanying drawings in which

[0046] FIGS. 1a-1c are cross sectional views of a contaminant sensor according to a first embodiment of the invention,

[0047] FIGS. 2a-2c are cross sectional views of a contaminant sensor according to a second embodiment of the invention,

[0048] FIGS. 3-9 are cross sectional views of a contaminant sensors according to various embodiments of the invention,

[0049] FIG. 10 is a diagrammatic view of a lubrication system according to an embodiment of the invention, and

[0050] FIGS. 11-15 illustrate contaminant sensors according to an embodiment of the invention arranged at various positions in a lubrication system.

DETAILED DESCRIPTION OF THE DRAWINGS

[0051] FIGS. 1a-1c are cross sectional views of a contaminant sensor 1 according to a first embodiment of the invention. In FIG. 1a the contaminant sensor 1 is not activated, in FIG. 1b the contaminant sensor 1 is partly activated, and in FIG. 1c the contaminant sensor 1 is fully activated.

[0052] The contaminant sensor comprises a sensor housing 2 having a permanent magnet 3 arranged movably therein. A resilient member, in the form of a flexible disc 4 (or a leaf spring) is coupled to the permanent magnet 3 and to a distance member 5. The distance member 5 is thereby coupled to the permanent magnet 3, via the flexible disc 4, and the position of the distance member 5 inside the sensor housing 2 is therefore determined by the position of the permanent magnet 3.

[0053] A sensor element, in the form of a distance sensor 6, is arranged partly inside the sensor housing 2, and is arranged to detect a distance between an end part of the distance sensor 6 and the distance member 5. Since this distance is defined by the position of the distance member 5 inside the sensor housing 2, the distance is a measure for a displacement of the permanent magnet 3.

[0054] The contaminant sensor 1 can be arranged in a lubricant flow in such a manner that the part of the sensor housing 2, which is arranged opposite to the position of the distance sensor 6, is arranged in contact with the lubricant. Thereby magnetizable contaminants present in the lubricant flow will be attracted towards the contaminant sensor 1 and collected on an outer surface of the sensor housing 2, due to the magnetic field generated by the permanent magnet 3. Furthermore, magnetizable contaminants being attracted towards the contaminant sensor 1 in this manner will remain attached to the sensor housing 2, due to the magnetic field. This will be described further below.

[0055] In FIG. 1a no contaminants have been attracted towards the contaminant sensor 1, and therefore no contaminants have been collected on the outer surface of the sensor housing 2. As a consequence, the permanent magnet 3 is arranged as close to the distance sensor 6 as possible, and the flexible disc 4 is in a relaxed state.

[0056] In FIG. 1b some contaminants 7 have been collected at the outer surface of the sensor housing 2. This has caused the permanent magnet 3 to be attracted by the collected contaminants 7, thereby moving the permanent magnet 3 towards the collected contaminants 7, against a biasing force provided by the flexible disc 4. Accordingly, the distance member 5 has been moved away from the distance sensor 6, i.e. the distance measured by the distance sensor 6 has increased.

[0057] In FIG. 1c a larger amount of contaminants 7 has been collected at the outer surface of the sensor housing 2. This has caused the permanent magnet 3 to be moved closer to the collected contaminants 7. Thereby the distance member 5 has been moved further away from the distance sensor 6, i.e. the distance measured by the distance sensor 6 has been further increased. This has caused the distance measured by the distance sensor 6 to increase above a predefined threshold value, indicating that the amount of collected contaminants 7 is above a given threshold value. If a certain amount of contaminants 7 is collected within a certain amount of time, this is an indication that a high concentration of magnetizable contaminants 7 is present in the lubricant flow. This may be due to damage or wear on moving parts being lubricated by means of the lubrication system, and therefore an indicator generates an alert in this case, e.g. in order to inform an operator that an inspection of the lubrication system is required.

[0058] When the permanent magnet 3 is moved as described above, it moves against the biasing force provided by the flexible disc 4. This ensures that the permanent magnet 3 moves gradually, and that the displacement of the permanent magnet 3 provides a suitable measure for the amount of magnetizable contaminants 7 which has been collected at the outer surface of the sensor housing 2.

[0059] FIGS. 2a-2c are cross sectional views of a contaminant sensor 1 according to a second embodiment of the invention. In FIG. 2a the contaminant sensor 1 is not activated, in FIG. 2b the contaminant sensor 1 is partly activated, and in FIG. 2c the contaminant sensor 1 is fully activated.

[0060] The contaminant sensor 1 of FIGS. 2a-2c is very similar to the contaminant sensor 1 of FIGS. 1a-1c, and it will therefore not be described in detail here.

[0061] As compared to the embodiment illustrated in FIGS. 1a-1c, in the contaminant sensor 1 of FIGS. 2a-2c, the flexible disc has been replaced by a compressible spring 8, and the distance member 5 has a different shape. Accordingly, the permanent magnet 3 is moved against a biasing force provided by the compressible spring 8, but otherwise the contaminant sensor 1 of FIGS. 2a-2c operates essentially as described above with reference to FIGS. 1a-1c.

[0062] FIG. 3 is a cross sectional view of a contaminant sensor 1 according to a third embodiment of the invention. The contaminant sensor 1 is shown in a fully activated state. The contaminant sensor 1 of FIG. 3 is very similar to the contaminant sensor 1 of FIGS. 1a-1c, and it will therefore not be described in detail here.

[0063] In the contaminant sensor 1 of FIG. 3 the distance element 5 is in the form of a disc mounted on a rod, which is attached to the flexible disc 4. This allows the distance sensor 6 to be arranged relatively far away from the permanent magnet 3, while the distance being measured by the distance sensor 1, i.e. the distance to the disc of the distance element 5, is relatively small.

[0064] FIG. 4 is a cross sectional view of a contaminant sensor 1 according to a fourth embodiment of the invention. The contaminant sensor 1 is shown in a fully activated state. The contaminant sensor 1 of FIG. 4 is very similar to the contaminant sensor 1 of FIG. 3, and it will therefore not be described in detail here.

[0065] In the contaminant sensor 1 of FIG. 4, the flexible disc 4 is coupled to the permanent magnet 3 via an extension member 9. The extension member 9 could, e.g., be a steel wire. This allows the permanent magnet 3 to be arranged even further from the distance sensor 6, while having the flexible disc 4 arranged close to the permanent magnet 3. However, it may still be envisaged that the flexible disc 4 is arranged far away from the permanent magnet 3.

[0066] FIG. 5 is a cross sectional view of a contaminant sensor 1 according to a fifth embodiment of the invention. Similarly to the embodiments described above, the contaminant sensor 1 comprises a sensor housing 2 having a permanent magnet 3 arranged movably therein. The part of the contaminant sensor 1 where the permanent magnet 3 is positioned can be arranged in contact with a lubricant flow, and magnetizable contaminants can be collected at an outer surface of the sensor housing 2, due to the magnetic field provided by the permanent magnet 3, essentially as described above.

[0067] The permanent magnet 3 is coupled to a resilient member, in the form of a bellow 10. A sensor element, in the form of a pressure sensor 11, is arranged partly inside the sensor housing 2, in such a manner that it measures the pressure, P1, inside the bellow 10.

[0068] When the permanent magnet 3 is moved towards the contaminants collected at the outer surface of the sensor housing 2, as described above, the pressure inside the bellow 10 decreases. This change in pressure is detected by the pressure sensor 11, and provides a suitable measure for the displacement of the permanent magnet 3, due to the contaminants collected on the outer surface of the sensor housing 2. Accordingly, the measured pressure provides a suitable measure for the amount of contaminants which has been collected on the outer surface of the sensor housing 2. Thus, when the measured pressure decreases below a predefined threshold value, an indicator generates an alert signal.

[0069] According to this embodiment, the actual displacement of the permanent magnet 3 may be very small, in particular if a liquid is arranged inside the bellow 10. However, the changes in pressure inside the bellow 10, due to the small displacement of the permanent magnet 3, may be detectable.

[0070] FIG. 6 is a cross sectional view of a contaminant sensor 1 according to a sixth embodiment of the invention. The contaminant sensor 1 of FIG. 6 is very similar to the contaminant sensor 1 of FIG. 5, and it will therefore not be described in detail here.

[0071] In the contaminant sensor 1 of FIG. 6, the pressure sensor 11 is arranged to measure a pressure, P2, prevailing inside a closed portion of the sensor housing 2, but outside the bellow 10. The bellow 10 is also arranged inside the closed portion of the sensor housing 2.

[0072] When the permanent magnet 3 is displaced as described above, and the pressure, P1, inside the bellow 10 thereby decreases, the pressure, P2, prevailing in the closed portion of the sensor housing increases. Thus, according to this embodiment, an indicator generates an alert signal when the measured pressure, P2, increases above a predefined threshold value.

[0073] FIG. 7 is a cross sectional view of a contaminant sensor 1 according to a seventh embodiment of the invention. The contaminant sensor 1 of FIG. 7 is very similar to the contaminant sensor 1 of FIG. 5, and it will therefore not be described in detail here.

[0074] In the contaminant sensor 1 of FIG. 7, the pressure sensor 11 is arranged to measure the pressure, P1, inside the bellow 10, as well as the pressure, P2, prevailing in the closed portion of the sensor housing 2. Accordingly, a differential pressure across the wall of the bellow 10 can be obtained by means of the pressure sensor 11. This provides a more accurate measure for the displacement of the permanent magnet 3, because any effects caused by changes in the ambient pressure or ambient temperature will only influence the absolute pressures, P1 and P2, but not the differential pressure across the wall of the bellow 10.

[0075] FIG. 8 is a cross sectional view of a contaminant sensor 1 according to an eighth embodiment of the invention. Similarly to the embodiments described above, the contaminant sensor 1 of FIG. 8 comprises a sensor housing 2 having a permanent magnet 3 arranged movably therein. The permanent magnet 3 is coupled to a resilient member, in the form of a deformable pad 12. When the permanent magnet 3 is moved, because it is attracted towards contaminants collected on the exterior surface of the sensor housing, the deformable pad 12 is squeezed by the permanent magnet 3, and thereby the deformable pad 12 undergoes deformation in the form of compression. The degree of deformation of the deformable pad 12 depends upon the displacement of the permanent magnet 3, and thereby on the amount of contaminants which has been collected on the outer surface of the sensor housing 2.

[0076] The deformable pad 12 is provided with sensor means (not visible), e.g. in the form of a strain gauge or a piezo resistive element embedded in or mounted on the deformable pad 12, which measures the amount of deformation of the deformable pad 12. This results in an electrical signal, which is supplied to an electronics box 13. When the electrical signal received at the electronics box 13 reaches a level which indicates that a certain amount of contaminants has been collected on the outer surface of the sensor housing 2, an indicator generates an alert.

[0077] FIG. 9 is a cross sectional view of a contaminant sensor 1 according to a ninth embodiment of the invention. The contaminant sensor 1 of FIG. 9 is very similar to the contaminant sensor 1 of FIG. 8, and it will therefore not be described in detail here.

[0078] In the contaminant sensor 1 of FIG. 9, the deformable pad 12 is coupled to the permanent magnet 3 at an end which is facing away from the part of the sensor housing 2 where the contaminants are collected. Thus, when the permanent magnet 3 is moved, as contaminants are collected on the outer surface of the sensor housing 2, the deformable pad 12 is stretched, i.e. it undergoes deformation in the form of stretching. The degree of deformation is detected, essentially as described above with reference to FIG. 8.

[0079] FIG. 10 is a diagrammatic view of a lubrication system 14 according to an embodiment of the invention. The lubrication system 14 is arranged for providing lubrication to a number of moving parts of a wind turbine.

[0080] The lubrication system 14 comprises a lubricant tank 15, a pump 16, a number of filters 17, a heat exchanger 18, and a distributor 19. Lubricant is pumped from the lubricant tank 15, by means of the pump 16, through the filters 17 and the heat exchanger 18 to the distributor 19. In the distributor 19 the available lubricant is distributed among a main bearing system 20, a gear system 21 and a generator 22. The main bearing system 20, the gear system 21 and the generator 22 are lubricated by means of the lubricant, and the lubricant is subsequently returned to the lubricant tank 15.

[0081] The lubrication system 14 is provided with one or more contaminant sensors, according to an embodiment of the invention, mounted in one or more of the positions 23. Thus, the presence of magnetizable contaminants in the lubricant flowing in the lubrication system 14 can be detected in the manner described above.

[0082] FIGS. 11-15 illustrate contaminant sensors 1 according an embodiment of the invention, arranged in various positions in a lubrication system. The lubrication system could, e.g., be the lubrication system 14 of FIG. 10.

[0083] FIG. 11 illustrates three possible positions of contaminant sensors 1 near an outlet 24 from a lubricant consumer. The lubricant consumer could, e.g., be a main bearing system, a gear system or a generator of a wind turbine, as illustrated in FIG. 10.

[0084] In a wind turbine, the drive train, and thereby also the main bearing system, the gear system and the generator, are inclined slightly relative to a horizontal direction. Thereby an outlet 24 from one of these lubricant consumers is also tilted slightly relative to a horizontal direction, as illustrated in FIG. 11. Therefore the force of gravity will cause the lubricant leaving the lubricant consumer via the outlet 24 to move along the direction illustrated by arrows 25.

[0085] In order to ensure that the contaminant sensors 1 are brought into contact with the lubricant flow, and that magnetizable contaminants present in the lubricant flow are brought to a position in the vicinity of one of the contaminant sensors 1, the contaminant sensors 1 are arranged in positions where the lubricant is trapped, or where the lubricant is naturally led by means of the force of gravity.

[0086] FIG. 12 illustrates another part of a lubrication system, in the form of a lubricant pipe 26 with a relatively large diameter. Due to the large diameter of the lubricant pipe 26, the lubricant flows relatively slowly through the lubricant pipe 26. Furthermore, the lubricant pipe 26 is slightly inclined relative to a horizontal direction, and therefore the lubricant moves along the direction indicated by arrow 27, due to the force of gravity.

[0087] Two contaminant sensors 1a, 1b are mounted on a lower part of the lubricant pipe 26. Thereby it is ensured that the lubricant is led past the contaminant sensors 1.

[0088] One of the contaminant sensors 1a has a sensor housing which is arranged substantially in alignment with an outer wall of the lubricant pipe 26. This provides a good contact between the contaminant sensor 1a and the lubricant flowing in the lubricant pipe 26.

[0089] The other contaminant sensor 1b has a sensor housing which is arranged at a small distance from the outer wall of the lubricant pipe 26. Thereby a small cavity is formed between the sensor housing and the interior of the lubricant pipe 26, the cavity being in open contact with the interior of the lubricant pipe 26. This has the consequence that some of the lubricant flowing in the lubricant pipe 26 is trapped in the cavity. Thereby it is ensured that magnetizable contaminants present in the lubricant which is trapped in the cavity are actually collected by the contaminant sensor 1b.

[0090] The contaminant sensors 1a, 1b are each mounted in a holder 28. This allows the contaminant sensors 1a, 1b to be removed from the lubrication system, along with any collected contaminants, e.g. in order to inspect the contaminant sensors 1a, 1b. A third holder 28 is shown, which does not have a contaminant sensor mounted therein.

[0091] FIG. 13 illustrates yet another part of a lubrication system, in the form of a substantially vertical lubricant pipe 29. The lubricant flows through the lubricant pipe 29 along the direction indicated by the arrows 30, i.e. in an upwards direction, against the force of gravity.

[0092] A check valve 31 is arranged in the lubricant pipe 29, in order to prevent lubricant from flowing in a direction opposite to the direction indicated by the arrows 30. Lubricant passing the check valve 31 is forced towards the walls of the lubricant pipe 20, as indicated by arrows 32. A contaminant sensor 1 is mounted on the lubricant pipe 29 at a position immediately downstream with respect to the check valve 31, i.e. at a position where the lubricant is forced towards the walls of the lubricant pipe, and thereby towards the contaminant sensor 1. Thereby it is ensured that the contaminant sensor 1 is brought into contact with the lubricant flowing in the lubricant pipe 29.

[0093] FIG. 14 illustrates yet another part of a lubrication system, also in the form of a substantially vertical lubricant pipe 33, having a relatively small diameter. Lubricant flowing through the lubricant pipe 33 flows substantially along the direction indicated by arrow 34, i.e. in a substantially upwards direction. A contaminant sensor 1 is mounted on the lubricant pipe 33.

[0094] Since the diameter of the lubricant pipe 33 is relatively small, the lubricant flows through the lubricant pipe 33 at a relatively high speed. There is therefore a risk that the lubricant, along with any contaminants contained therein, simply passes the contaminant sensor 1, and that the contaminants are thereby not collected by the contaminant sensor 1. In order to ensure that the contaminant sensor 1 is brought into contact with the lubricant, a diverter 35 is arranged inside the lubricant pipe 33, in order to direct the lubricant towards the contaminant sensor 1, and possibly slow down the lubricant flow.

[0095] FIG. 15 illustrates yet another part of a lubrication system, in the form of a substantially horizontal lubricant pipe 36, having a relatively small diameter. Lubricant flowing through the lubricant pipe 36 flows substantially along the direction indicated by arrow 37, i.e. substantially from left to right in the Figure. A contaminant sensor 1 is mounted on a lower part of the lubricant pipe 36. Thereby the force of gravity will lead the lubricant flowing in the lubricant pipe 36 towards the contaminant sensor 1.

[0096] However, since the diameter of the lubricant pipe 36 is relatively small, the lubricant flows through the lubricant pipe 36 at a relatively high speed, and there is therefore a risk that contaminants present in the lubricant are not collected by the contaminant sensor 1, as described above, with reference to FIG. 14. Therefore a diverter 35 is arranged inside the lubricant pipe 36, in order to direct the lubricant towards the contaminant sensor 1, and possibly slow down the lubricant flow.