Remote multisensor optical particle monitor for flowing fluid systems
Inventors
Tucker, John E. • Reintjes, John F.
Assignees
NAVY GOVERNMENT OF United States, Secretary of • US Department of Navy
Publication Number
US-8582100-B1
Publication Date
2013-11-12
Expiration Date
2033-06-18
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Abstract
An optical fluid monitoring system for imaging debris and other particles in a flowing fluid. The system can have multiple sensors (camera and viewing port) connected to a single, remotely located, laser and computer. The system can also include multiple lasers, viewing ports and cameras to be located at different locations in a flow, with each sensor being configured to image a different particle size range. The system can simultaneously image fluid flows on different pieces of equipment.
Core Innovation
The invention relates to an optical fluid monitoring system designed for imaging particles in flowing fluids within at least one conduit. The system includes multiple optical sensors positioned along the conduit, each configured to transmit laser optical energy through a transparent viewing window transverse to the flow direction. Each sensor has an optical imaging system to receive the transmitted optical energy after it passes through the fluid flow and to image particles suspended in the fluid.
The invention addresses the problem found in prior art where single sensors with co-located lasers and cameras are limited to imaging particle sizes in a confined range and location. The system overcomes this by using multiple sensors arranged either in series or parallel, each configured to image different particle size ranges by adjusting conduit thickness to place the target particles in the optical near field of the imaging system. It also utilizes filters between sensors to exclude particles larger than a predetermined size from downstream sensors, enabling simultaneous monitoring of different size ranges across one or more fluid flows.
Further, the system can employ either individual lasers at each sensor or a single laser source coupled via optical fibers to multiple sensors. A single or multiple computer processors can classify particle sizes and shapes from the images received, with processors located remotely from the sensors. The invention allows monitoring of fluids in multiple conduits, including different fluid systems associated with various pieces of equipment, providing a broader particle size range, redundancy, and remote operation capabilities.
Claims Coverage
The patent claims cover multiple inventive features related to an optical fluid monitoring system with a plurality of sensors configured to image different particle size ranges, laser energy transmission, and image processing.
Imaging particles using multiple sensors with size-specific conduit thicknesses
The system comprises a plurality of optical sensors positioned along a conduit to transmit laser energy across the fluid flow and image particles. The first sensor images larger particle size ranges with a larger conduit thickness, and a second sensor images smaller particle size ranges with a smaller conduit thickness, ensuring particles are within the optical near field.
Integration of lasers with sensors and wavelength differentiation
Each optical sensor may include its own laser, with lasers possibly having different wavelengths. Optical fibers can transmit laser energy to the viewing windows from the lasers.
Single laser coupled to multiple sensors
A single laser can be operatively coupled to all optical sensors, distributing laser energy via multiple optical fibers to each sensor's viewing window.
Imaging systems utilizing cameras and lenses
Each imaging system includes a camera and a lens disposed between the camera and the conduit viewing window, enabling image capture of particles in the fluid.
Use of filters to exclude undesirably sized particles
Filters of predetermined mesh size exclude particles larger than a set threshold from reaching downstream sensors that image smaller particle ranges.
Centralized image processing with a single computer processor
A single computer processor receives images from all imaging systems and is programmed to classify particle shapes and sizes from the image data.
Distributed processing with processors at each sensor
Each optical sensor may include its own computer processor connected to the imaging system, classifying particle shapes and sizes locally, with processors able to be located remote from the sensors.
Adaptation for imaging particles in multiple conduits and different equipment
The system is adapted to image particles in at least two different conduits, with at least one sensor positioned along each conduit. Each conduit can be part of a different piece of equipment.
The claims collectively cover an optical fluid monitoring system featuring multiple sensors arranged to image different particle size ranges by controlling conduit thickness, flexible laser arrangements including single or multiple lasers with optical fiber transmission, imaging systems with camera and lens, particle exclusion filters, and centralized or distributed computer processing, adapted for multi-conduit and multi-equipment applications.
Stated Advantages
Provides information about a broader particle size range than previous near field optical fluid particle monitoring systems.
Offers redundancy in monitoring to ensure continued operation, especially beneficial for equipment that is difficult or dangerous to access.
Enables simultaneous monitoring of different fluids or fluid systems, such as engines, transmissions, and bearings across varied industrial installations.
Allows components like lasers and computer processors to be located remotely from the sensors and conduits, permitting long-distance operation limited only by optical fiber transmission capability.
Documented Applications
Monitoring particles in flowing fluids such as lubricating and power transmission fluids, cooling liquids, water mixtures, fuels, and gases.
Simultaneous imaging of particle sizes in multiple fluids within different conduits, including fluids in various components of aircraft, ships, oil drilling platforms, and power generating stations.
Condition monitoring of mechanical systems by imaging debris and wear particles in lubricating fluids, useful for early wear detection and assessing machinery condition.
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