Numerical Approach and Verification Method for Improving the Sensitivity of Ferrous Particle Sensors with a Permanent Magnet

This study aimed to improve the sensitivity of ferrous particle sensors used in various mechanical systems such as engines to detect abnormalities by measuring the number of ferrous wear particles generated by metal-to-metal contact. Existing sensors collect ferrous particles using a permanent magnet. However, their ability to detect abnormalities is limited because they only measure the number of ferrous particles collected on the top of the sensor. This study provides a design strategy to boost the sensitivity of an existing sensor using a multi-physics analysis method, and a practical numerical method was recommended to assess the sensitivity of the enhanced sensor. The sensor’s maximum magnetic flux density was increased by around 210% compared to the original sensor by changing the core’s form. In addition, in the numerical evaluation of the sensitivity of the sensor, the suggested sensor model has improved sensitivity. This study is important because it offers a numerical model and verification technique that may be used to enhance the functionality of a ferrous particle sensor that uses a permanent magnet.