In order to monitor the diagnosis of mechanical equipment by monitoring the metal wear particles carried in large aperture lubricating oil tubes, the simulation optimization structure design was carried out based on the traditional three-coil inductance wear particle sensor. The numerical model of electromotive force induced by the wear particle sensor was established, and the coil distance and coil turns were simulated by finite element analysis software. When permalloy is covered on the surface of the excitation coil and induction coil, the background magnetic field at the air gap increases, and the induced electromotive force amplitude generated by wear particles is increased. The effect of alloy thickness on the induced voltage and magnetic field was analyzed to determine the optimum thickness, and increase the induction voltage of the alloy chamfer detection at the air gap. The optimal parameter structure was determined to improve the detection ability of the sensor. Ultimately, by comparing the extreme values of the induced voltage of various types of sensors, the simulation determined that the minimum allowable detection of the optimal sensor was 27.5 µm ferromagnetic particles.

The detection of wear debris in lubricating oil is effective for determining current equipment operating conditions for fault diagnosis. In this paper, a permanent magnet ferromagnetic wear debris sensor is proposed that is composed of a compact structure and a detection coil that generates an induced voltage when wear debris passes through a magnetic field. A three-dimensional model of the sensor is established, the internal axisymmetric high-gradient magnetic field of the sensor is analyzed, and a mathematical model of the sensor signal is proposed. The effects of the air gap structure of the sensor and the relative permeability, velocity, and volume of the wear debris on the sensor performance are analyzed. The correctness of the theoretical results is proven by single particle experiments, and the sensor is calibrated to achieve quantitative analysis of the wear debris.

Enhanced plasticity is obtained in a structurally rejuvenated Zr-based bulk metallic glass (BMG) that has been treated via cryogenic thermal cycling (CTC) for one hundred cycles. More than one primary shear band is activated due to the structural rejuvenation, which can inhibit the jerky and system-spanning propagation of shear bands to generate sluggish shear-dynamics. These are mapped to the slip statistics, including the decreased critical avalanche size, the much longer avalanche duration of large (system-spanning) slips, and a great number of small avalanches. Moreover, the universal scaling of slip avalanches for three applied stress ranges is addressed to predict the applied stress at which the failure avalanche appears most. These results indicate that slip statistics can be the fingerprints to show how much the BMG is rejuvenated, and the failure avalanche provides a good opportunity to intervene in the failure of BMGs in advance.