A magic wand array eddy current probe, its sensor and detection method

Abstract

The application discloses a magic wand type array eddy current probe, a sensor and a detection method, and relates to a sensor 121 for eddy current detection of a crack of a detected object 11 of a large metal device, which comprises a coil 1211 and a main body 1212, the main body 1212 is arranged in a cubic structure, and three groups of same coils are evenly and orthogonally wound on the cubic structure, wherein, six surfaces of the cubic main body of the sensor form the same non-directional eddy current detection surfaces which intersect with each other in pairs during detection. The detection probe formed by a plurality of non-directional cubic eddy current detection sensor arrays is connected in a relatively rotatable and translational mode, a magic wand type array eddy current probe structure is realized, the square orthogonal coils have the characteristics of detection capability in multiple directions, a magic wand type (or snake type) array is formed, and the deformable orthogonal non-directional eddy current sensor solves the detection problem of irregular and special-shaped metal workpieces in large on-site in-service devices.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology, specifically to array-type eddy current sensors, and particularly to a magic wand-type array eddy current probe, its sensor, and testing method. Background Technology

[0002] In service of major equipment, there are various irregularly shaped metal components, including some with welds. Because these components must withstand certain forces (including shearing, cutting, bending, and torsion) during operation, fatigue cracks are easily generated. Typically, ultrasonic, magnetic particle, and eddy current methods are used for non-destructive testing. However, ultrasonic testing requires a coupling agent, making it inconvenient to use, and magnetic particle testing causes environmental pollution and is difficult to implement on irregular surfaces. Therefore, currently, neither of these methods is suitable for inspecting such workpieces in service, especially those with anti-corrosion coatings. With the invention of orthogonal omnidirectional eddy current probes, more and more owners are adopting eddy current testing. This is because eddy current testing can penetrate anti-corrosion layers without surface treatment, and because it uses orthogonal omnidirectional probes, it is insensitive to uneven surfaces (such as welds), thus its application is becoming increasingly widespread. However, this single-probe eddy current method is not very efficient. (See attached...) Figure 1 The main body of the object 11 shown has multiple irregular surfaces. If an array of orthogonal non-directional probes is used to improve work efficiency, a special array probe must be customized. In reality, there are many different irregular shapes and structures, making it impossible to use a universal probe that mimics the shape, which limits the promotion of this technology.

[0003] To address the above-mentioned shortcomings, the present invention adopts the following technical solution. Summary of the Invention

[0004] The purpose of this invention is to provide a magic wand-type array eddy current probe, its sensor, and detection method. The disclosed technical solution is as follows: An eddy current detection sensor includes coils and a main body. The main body is configured as a cube, with three identical coils uniformly and orthogonally wound in pairs around the cube. During detection, the six faces of the cube form identical, intersecting, non-directional eddy current detection surfaces. In other words, the six faces of the cube form identical non-directional detection surfaces.

[0005] Furthermore, the three sets of identical coils alternately serve as transmitting and receiving coils within a time interval, selecting the optimal detection signal as the desired detection result. Within each time cycle, the six faces of the cube of the detection sensor take turns performing the same detection process, enabling detection regardless of which face of the cube contacts the detection surface of the object. Any face can be flexibly selected as the eddy current detection contact surface, and when the sensors are combined into an array of eddy current detection probes, any face can be freely adjusted as the detection surface.

[0006] Furthermore, the three sets of identical coils repeat a time interval cycle. Within each time interval cycle, each of the three coils alternately performs one transmission and one reception, selecting the optimal detection signal as the desired detection result. Within a time period, the six faces of the detection sensor complete the same non-directional detection process in turn. This eliminates the need to select and attach a coil to the detection surface of the object for each detection; instead, the detection sensor only needs to be attached to the detection surface, and the detection is performed rapidly in turn within the time period set by the detection instrument software. This omits the step of selecting the detection sensor coil by the eddy current detection probe, thus simplifying the detection device.

[0007] Furthermore, the optimal detection signal is set as the criterion for determining the side of the six detection faces of the detection sensor that is actually being detected. Alternatively, coils corresponding to the markings on the six faces of the cube of the detection sensor can be added as identifiers for the specific detection face.

[0008] The present invention also discloses a magic wand-type array eddy current probe, comprising an array of more than one of the aforementioned eddy current detection sensors arranged in an array. The eddy current detection sensors arranged in the array are connected by mutual movement of several cubic eddy current detection sensors. During detection, the relative positions of the sensors are adjusted to form an arrangement structure on curved surfaces at different positions. The different curved surface shapes formed correspond to different detection surfaces of the irregularly shaped object being detected.

[0009] Furthermore, the movable connection is configured as a rotating connection structure between the near sides of the sensors, wherein a protrusion on one sensor surface engages with a slot on the other sensor surface to form a rotating connection.

[0010] Furthermore, the movable connection is configured such that the sensors near their sides move relative to each other in a connecting structure. A protrusion on one sensor surface guides the connection to a guide groove on the other sensor surface, forming a linear movable connection. This connection method is similar to the connection between components in a Rubik's Cube. In a preferred embodiment, the guide groove of the linear movable connection is cross-shaped or a straight line in one direction. The rotary connection structure, combined with the cross-shaped guide groove, allows the position adjustment between the two sensors of the array-type eddy current detection probe to be adjusted in any direction, similar to rotating and moving in a Rubik's Cube, achieving a better fit to different irregularly shaped detection surfaces.

[0011] Furthermore, the movable connection is configured to connect several cubic sensors at one corner to form an array-type eddy current probe. The movable connector connection method allows for three-dimensional adjustment of the angle between each sensor and the distance between the detection surfaces, forming various irregular structures to adapt to different shapes of detection objects.

[0012] This invention also discloses a magic wand array eddy current detection method, characterized by using the array eddy current probe described above, and the specific method steps are as follows: a. Adjustment of the arrangement and position of eddy current detection sensors: Place the array of eddy current probes against the detection surface of the object being tested, and adjust the connection angle and position between each sensor so that the eddy current detection probes form a curved surface that fits the detection surface of the object being tested and is attached to the detection surface of the object being tested; b. Detection parameter setting: Set the periodic time period, and the sequence in which the three coils of each detection sensor of the eddy current detection probe take turns transmitting and receiving once during the periodic time, and enter the detection stage; c. Actual detection: During the periodic time period, the three coils of each eddy current detection sensor take turns receiving and transmitting once in sequence: the best data of the detection signal is extracted as the detection result data, or the coil signal marked on each detection surface is used as the detection result data; d. Selection of test data: After repeated testing, select the best test result data as the test result data of the tested object.

[0013] Furthermore, in the actual detection process of step c, when selecting the optimal detection result data, if the detection signals of two or more sets of coils are similar in strength, they are simultaneously used as the detection result data, indicating that two or more detection surfaces of the detection sensor are simultaneously detecting the detection surfaces of the irregularly shaped object. When the included angle of the tangents of the similar curved surfaces of the irregularly shaped metal object being detected is less than a right angle, the two surfaces of the cube of the detection sensor can simultaneously detect different surface positions of the object being detected, improving the flexibility and efficiency of the detection.

[0014] Based on the above technical solutions, the present invention has the following beneficial effects: 1. The present invention provides an eddy current detection sensor by setting three sets of identical coils uniformly and orthogonally wound in pairs around a cube structure, thereby achieving the formation of identical non-directional detection sensors on all six faces of the cube; 2. The present invention provides a detection probe formed by an array of multiple non-directional cube eddy current detection sensors, with a connection structure between the sensors that allows for relative rotation and translation, realizing a magic wand-like array eddy current probe structure. Utilizing the characteristic that its square orthogonal coils have detection capabilities in multiple directions, it forms a magic wand-shaped (or snake-shaped) array, enabling deformable orthogonal non-directional eddy current sensing. This invention provides a method for detecting irregularly shaped metal workpieces in large, in-service equipment. Furthermore, the invention employs a magic wand-type array eddy current detection method. This method involves a detection process where the three sensor coils of the detection sensor sequentially transmit and receive signals once within a periodic time interval. In one cycle, each of the six surfaces of the detection sensor completes one detection, selecting the optimal detection signal as the detection result data. This process can then be repeated periodically. By using software processing to replace the selection of the detection surface of the detection sensor in the detection probe, the hardware operation structure and program of the detection probe are simplified, enabling more flexible selective detection. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the detection device in use according to the preferred embodiment of the present invention; Figure 2 This is a schematic diagram of the detection sensor structure according to the preferred embodiment of the present invention; Figure 3 This is a schematic diagram of the detection device in use according to the preferred embodiment of the present invention; Figure 4 This is a schematic diagram of the sensor connection structure in the array-type eddy current detection probe of the preferred embodiment of the present invention; Figure 5 This is a schematic diagram of the connection surface structure in the detection sensor connection structure of the eddy current detection probe according to the preferred embodiment of the present invention; Figure 6 This is a schematic diagram of the connection surface structure in the detection sensor connection structure of the eddy current detection probe according to the preferred embodiment of the present invention; Figure 7 This is a schematic diagram of a detection sensor detecting multiple surfaces in the preferred embodiment of the detection device of the present invention. Figure 8 A schematic diagram of the sensor connection structure in an array-type eddy current detection probe, which is another embodiment of the preferred embodiment of the present invention; Figure 9 A schematic diagram of the sensor connection structure in an array-type eddy current detection probe, which is a preferred embodiment of the present invention. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0017] like Figure 1 and Figure 2 As shown, an eddy current detection sensor, 121, is used for eddy current detection of a large metal device 11. It includes a coil 1211 and a main body 1212. The main body 1212 is a cube structure with three sets of identical coils evenly and orthogonally wound in pairs around the cube. During detection, the six faces of the cube form identical, intersecting, non-directional eddy current detection surfaces. In other words, the six faces of the cube form identical non-directional detection surfaces.

[0018] like Figure 2 As shown, three sets of identical coils alternately act as transmitting and receiving coils within a time interval, selecting the optimal detection signal as the desired detection result. Within each time cycle, the six faces of the cube of the detection sensor perform the same detection process in turn, enabling detection regardless of which face of the cube contacts the detection surface of the object. Any face can be flexibly selected as the eddy current detection contact surface. When the sensors are combined into an array of eddy current detection probes, any face can be arbitrarily adjusted as the detection surface. The three sets of identical coils repeat a time interval cycle, with each of the three coils alternately acting as both a transmitter and receiver within each time interval, selecting the optimal detection signal as the desired detection result. Within a time period, the six faces of the detection sensor perform the same non-directional detection process in turn. This eliminates the need to select the coil to be contacted with the detection surface for each detection; instead, the detection sensor only needs to be in contact with the detection surface, and the detection is performed rapidly in turn within a time period set by the detection instrument software. This omits the step of selecting the detection sensor coil for the eddy current detection probe, simplifying the detection device through software. The optimal detection signal setting is used as the criterion for determining the side of the sensor that is actually being detected among its six detection faces. Alternatively, coils corresponding to the markings on the six faces of the sensor cube can be added to further identify the specific detection face.

[0019] like Figure 1 and Figures 3 to 6 As shown, this invention also discloses a magic wand-type array eddy current probe 12, comprising an array of several or more eddy current detection sensors 121 arranged in an array. The arrayed eddy current detection sensors 121 are connected by several cubic eddy current detection sensors. During detection, the relative positions of the sensors are adjusted to form an arrangement structure on curved surfaces at different positions. The different curved surface shapes formed correspond to different detection surfaces of the irregularly shaped object being detected. Figure 1 As shown, the detection surfaces 1, 2, 3, 4, 5, and 6 of each detection sensor of the eddy current detection sensor 121 correspond to the irregular surfaces 1, 2, 3, 4, 5, and 6 of the object being detected, respectively.

[0020] The movable connection is configured as a rotating connection structure between the near sides of the sensors, wherein a protrusion 122 on one sensor surface engages with a slot 123 on the other sensor surface to form a rotating connection.

[0021] like Figure 5 and Figure 6 As shown, the movable connection is configured such that the sensors near their sides move relative to each other in a connecting structure. A protrusion on one sensor surface guides the connection to a guide groove on the other sensor surface, forming a linear movable connection. This connection method is similar to the connection between components in a Rubik's Cube. In a preferred embodiment, the guide groove of the linear movable connection is cross-shaped or a straight line in one direction. The rotary connection structure, combined with the cross-shaped guide groove, allows the position adjustment between the two sensors of the array-type eddy current detection probe to be adjusted in any direction, similar to the rotation and movement in a Rubik's Cube, achieving a better fit to different irregularly shaped detection surfaces.

[0022] like Figure 8 and Figure 9 As shown, the movable connection is set to connect several cubic sensors at one corner to form an array eddy current probe. The movable joint connection method adjusts the angle between each sensor and the distance between the detection surfaces in three dimensions to form various irregular structures that can be adapted to detection objects of different shapes.

[0023] This invention also discloses a magic wand array eddy current detection method, using the above-mentioned array eddy current probe, and the specific method steps are as follows: a. Adjustment of the arrangement and position of eddy current detection sensors: Place the array of eddy current probes against the detection surface of the object being tested, and adjust the connection angle and position between each sensor so that the eddy current detection probes form a curved surface that fits the detection surface of the object being tested and is attached to the detection surface of the object being tested; b. Detection parameter setting: Set the periodic time period, and the sequence in which the three coils of each detection sensor of the eddy current detection probe take turns transmitting and receiving once during the periodic time, and enter the detection stage; c. Actual detection: During the periodic time period, the three coils of each eddy current detection sensor take turns receiving and transmitting once in sequence: the best data of the detection signal is extracted as the detection result data, or the coil signal marked on each detection surface is used as the detection result data; d. Selection of test data: After repeated testing, select the best test result data as the test result data of the tested object.

[0024] In the actual detection process of step c, when selecting the optimal detection result data, if the detection signals of two or more sets of coils are similar in strength, they are simultaneously used as the detection result data. This indicates that two or more detection surfaces of the detection sensor are simultaneously detecting the detection surfaces of the irregularly shaped object. When the included angle of the tangents of the similar curved surfaces of the irregularly shaped metal object is less than a right angle, the two surfaces of the cube-shaped detection sensor can simultaneously detect different surface positions of the object, improving the flexibility and efficiency of the detection. Figure 7 As shown, in the usage state, the array-type eddy current detection sensor 12's detection sensor 121A simultaneously detects A1, A2, and A3 of the object being detected 11, while the detection sensor 121B simultaneously detects the object being detected 11 on both the vertical and horizontal planes.

[0025] The above is one embodiment of the present invention. Furthermore, it should be noted that any equivalent or simple variations made to the structure, features, and principles described in this patent concept are included within the scope of protection of this patent.

Claims

1. A magic wand-type array eddy current probe, characterized in that, It comprises an array of several cubic eddy current detection sensors. The main body of each cubic eddy current detection sensor is a cubic structure, with three sets of identical coils evenly and orthogonally wound around the cube. The array of cubic eddy current detection sensors is interconnected through mutual movement. During detection, the relative positions of the sensors are adjusted to form arrangement structures on curved surfaces at different positions. The different curved surface shapes formed correspond to different detection surfaces of the irregularly shaped object being detected. The movable connection is configured as follows: a rotary connection structure formed by a protrusion on one sensor surface engaging with a slot on another sensor surface; and / or a linear movable connection structure formed by a protrusion on one sensor surface guiding and connecting to a guide groove on another sensor surface; and / or a movable connection between one corner of several cubic sensors, allowing adjustment of the angle between the sensors and the distance between the detection surfaces in three dimensions.

2. The magic wand-type array eddy current probe according to claim 1, characterized in that, The guide groove of the linear moving connection is configured as a cross shape, or as a straight line in one direction.

3. A method for detecting eddy currents using a magic wand array, characterized in that... The specific steps of using the array eddy current probe according to claim 1 or 2 are as follows: a. Adjustment of the arrangement and position of eddy current detection sensors: Place the array of eddy current probes against the detection surface of the object being tested, and adjust the connection angle and position between each sensor so that the eddy current detection probes form a curved surface that fits the detection surface of the object being tested and is attached to the detection surface of the object being tested; b. Detection parameter setting: Set the periodic time period, and the sequence in which the three coils of each detection sensor of the eddy current detection probe will take turns transmitting and receiving once during the periodic time, and then enter the detection stage; c. Actual detection: During the periodic time period, the three coils of each eddy current detection sensor take turns receiving and transmitting once in sequence: the best data of the detection signal is extracted as the detection result data, or the coil signal marked on each detection surface is used as the detection result data; d. Detection data selection: After repeated testing, select the best detection result data as the detection result data of the tested object.

4. The method for detecting eddy currents using a magic wand array according to claim 3, characterized in that... In the actual detection in step c, when selecting the best detection result data, if the detection signals of two or more sets of coils are similar in strength, they are used as the detection result data at the same time, and it is determined that two or more detection surfaces of the detection sensor are simultaneously detecting the detection surface of the irregular object being detected.

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