A Microfluidic Coulter Counting Device for Metal Wear

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A Microfluidic Coulter Counting Device for Metal Wear A MICROFLUIDIC COULTER COUNTING DEVICE FOR METAL WEAR DETECTION IN LUBRICATION OIL A Thesis Presented to The Graduate Faculty of The University of Akron In Partial Fulfillment of the Requirements for the Degree Master of Science Srinidhi Veeravalli Murali December, 2008 A MICROFLUIDIC COULTER COUNTING DEVICE FOR METAL WEAR DETECTION IN LUBRICATION OIL Srinidhi Veeravalli Murali Thesis Approved: Accepted: _________________________ _________________________ Advisor Department Chair Dr. Jiang John Zhe Dr. Celal Batur _________________________ _________________________ Faculty Reader Dean of the College Dr. Joan Carletta Dr. George K. Haritos _________________________ _________________________ Faculty Reader Dean of the Graduate School Dr. Dane Quinn Dr. George R. Newkome _________________________ Date ii ABSTRACT Real time monitoring of lubrication oil quality has become an important issue in today’s military, transportation and manufacturing industries. Accurate condition monitoring methodologies are needed to effectively schedule maintenance downtime as well as to ensure the accomplishment of long-range military and commercial operations. The degradation of lubrication oil is typically from two sources: 1) the accumulation of metal wear particles and 2) degradation in the physical properties of the lubrication oil. During normal machine operation, small wear debris particles with sizes in the range of 1 to 10 microns are usually generated. When abnormal wear begins, larger particles in the range of 10 to 150 microns are generated. The particle population and size will increase gradually with time and this trend of growing particle population and size will increase until machine failure. Thus, continuous monitoring of wear debris in lubrication oil is critical to avoid catastrophic system failure of machines. This thesis demonstrates that the capacitance Coulter counting principle can be used to detect and count metal wear particles generated in lubrication oil. The Coulter counting principle is an established technique to count biological cells in an electrolyte solution. A Coulter counter consists of two reservoirs connected by a microchannel. When a particle is present in microchannel, it causes a change in resistance of the liquid- filled microchannel. As lubrication oil is non-conductive, the resistance changes due iii to the passage of a particle is difficult to measure. To overcome this, we monitor the change in capacitance formed between two electrodes in a microchannel. When a metal particle passes through the microchannel, a change in the capacitance can be detected owing to the difference in permittivity between the lubrication oil and the metal particle. To demonstrate the capacitive Coulter counting principle for metal particle detection in lubrication oil, a meso-sized device consisting of two parallel electrode plates immersed in SAE-5W30 motor oil was used to simulate a fluidic channel. Metal particles were dropped from the top of the channel and allowed to travel to the bottom. It was found that the passage of the metal particle did cause a capacitance pulse, monitored using a capacitive readout IC chip. It was found that the capacitance change increases as the particle size is increased. The demonstration using the meso-sized device indicates the possibility of using a microfluidic device for detection and counting metal wear particles in lubrication oil based on the Coulter counting principle. Furthermore, to validate the dynamic response of the measurement circuitry in a fluid environment for the microfluidic device using co-planar electrodes, we first test the microfluidic device for detection of Juniper scopulorum pollen and polystyrene particles in de-ionized water. Next, we present the use of a microfluidic sensor for electronic monitoring of wear debris in lubrication oil based on the capacitance measurement setup demonstrated earlier. Aluminum particles (size ranges from 15 to 25 µm in diameter) suspended in SAE-5W30 motor oil were used for device testing. When oil with aluminum particles was loaded, capacitive pulses due to passage of these particles were observed. The magnitude of the pulses is in the range of 2 to 7 femto-farads. The test results show the microfluidic device to be highly promising for use in online debris monitoring in lubrication oil. iv ACKNOWLEDGEMENTS Grateful acknowledgement is made to my Advisor, Dr. Jiang Zhe, for his constant guidance and mentoring through the project. I would like to thank my co-advisor Dr. Joan Carletta with all sincerity for her valuable suggestions in this project. My special thanks to Ashish V. Jagtiani for his help all through.Li Du, Hui Ouyang, Abhay Vasudhev and Xinggao Xia have been of great support in this project. I would also like to extend my heartfelt thanks to my fiancé Anup Viswanathan and my family for their constant support and prayers all through my study away from home. v TABLE OF CONTENTS Page LIST OF TABLES............................................................................................................. ix LIST OF FIGURES .............................................................................................................x CHAPTER I. INTRODUCTION............................................................................................................1 1.1 In situ monitoring of lubrication oil quality.................................................................1 1.2 Coulter counting principle ...........................................................................................3 1.3 Microfluidic sensor technology ...................................................................................4 1.4 Research objectives......................................................................................................4 II. BACKGROUND WORK ...............................................................................................7 2.1 Rotary machine maintenance techniques.....................................................................7 2.1.1 Condition monitoring..............................................................................................8 2.1.2 Wear debris monitoring ........................................................................................12 2.1.2.1. Spectrographic analysis ..................................................................................12 2.1.2.2. Ferrography.....................................................................................................13 2.1.2.3. Acoustic and ultrasonic sensors......................................................................14 2.1.2.4. Chip detectors / magnetic plugs......................................................................15 2.1.2.5. Inductive sensors.............................................................................................16 2.1.2.6. Particle counting .............................................................................................17 vi 2.1.2.7. Mesh / filter blockage .....................................................................................18 2.1.2.8. Gravimetric analysis .......................................................................................19 2.1.2.9. Coulter counters..............................................................................................19 2.1.3 Visual inspection monitoring................................................................................20 2.1.4. Vibration monitoring ...........................................................................................20 2.1.5. Performance monitoring ......................................................................................21 2.2 Summary....................................................................................................................22 III. CHARACTERIZATION OF THE MEASUREMENT IC MS3110...........................24 3.1 Working principle of MS3110 IC .............................................................................25 3.2 Static characterization of MS3110.............................................................................27 3.3 Dynamic characterization of MS3110 .......................................................................33 3.3.1 Response time of MS3110....................................................................................33 3.4 Summary....................................................................................................................40 IV. MESO-SCALE SENSOR WITH PARALLEL PLATE ELECTRODES...................41 4.1 Meso-sized device and experimental setup................................................................42 4.2 Finite element model..................................................................................................44 4.3 Results and discussion ...............................................................................................46 4.3.1 Instrumentation validation ....................................................................................46 4.3.2 Detection of conducting particles .........................................................................47 4.3.3 Comparison of experimental and simulation results for pulse height of particles..................................................................................47 4.3.4 Comparison of experimental and theoretical analysis for pulse width of particles ...................................................................................50 vii 4.4 Summary....................................................................................................................54
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