Wear-resistant and high-temperature-resistant array eddy current welding seam detection sensor

Abstract

The utility model relates to the technical field of array eddy current welding seam detection sensors, in particular to a wear-resistant and high-temperature-resistant array eddy current welding seam detection sensor which comprises a detection sensor body and further comprises an inductive probe arranged on one side of the detection sensor body, and a plurality of low-temperature co-fired ceramic substrates are arranged on the inner side of the inductive probe. A silver silk-screen printing coil is arranged on the inner surface of the low-temperature co-fired ceramic substrate. Under the action of the wear-resistant layer, the low-temperature co-fired ceramic substrate and the silver silk-screen printing coil, the sensor has the advantages of wear resistance, high temperature resistance and wide application range, and solves the problem that the working temperature of the conventional array eddy current welding seam detection sensor is generally limited to less than two hundred degrees centigrade in the use process, so that the sensor cannot be used for detecting the welding seam. The problems that the conventional array eddy current welding seam detection sensor cannot meet the requirement of a high-temperature environment and is poor in surface wear resistance, so that the application range of the array eddy current welding seam detection sensor is influenced are solved.

Description

TECHNICAL FIELD

[0001] The utility model relates to array eddy current weld joint detection sensor technical field, concretely is a kind of wear-resistant, high-temperature array eddy current weld joint detection sensor. BACKGROUND

[0002] Array eddy current weld joint detection sensor is a kind of equipment using eddy current principle to carry out weld joint detection, its core lies in the use of the probe formed by multiple independent coils, can scan weld joint and detect small defects comprehensively, array eddy current detection technology is widely applied in multiple fields, especially in the detection of aluminum alloy fusion weld joint, can quickly and accurately detect the small defects on the surface of weld joint, avoid many drawbacks in traditional coloring penetration detection.

[0003] At present, the working temperature of the existing array eddy current weld joint detection sensor during use is generally limited to below 200 degrees Celsius, which cannot meet the requirements of high-temperature environment, and the surface wear resistance is poor, which affects the application range of the array eddy current weld joint detection sensor. Therefore, we propose a wear-resistant and high-temperature array eddy current weld joint detection sensor. UTILITY MODEL CONTENTS

[0004] The utility model discloses a wear-resistant and high-temperature array eddy current weld joint detection sensor, which has the advantages of wear resistance, high-temperature resistance and wide application range. The problem of the working temperature of the existing array eddy current weld joint detection sensor during use being generally limited to below 200 degrees Celsius, which cannot meet the requirements of high-temperature environment, and the surface wear resistance being poor, which affects the application range of the array eddy current weld joint detection sensor, is solved.

[0005] To achieve the above-mentioned purpose, the utility model provides the following technical scheme: a wear-resistant and high-temperature array eddy current weld joint detection sensor, comprising a detection sensor body, further comprising:

[0006] The inductive probe is arranged on one side of the detection sensor body, the inner side of the inductive probe is provided with a plurality of low-temperature co-fired ceramic substrates, the inner surface of the low-temperature co-fired ceramic substrate is provided with a silver screen printing coil, and the plurality of low-temperature co-fired ceramic substrates are stacked, isostatic pressed and high-temperature sintered in order to form a three-dimensional coil;

[0007] The reinforcing layer is arranged outside the detection sensor body, and the outer side of the reinforcing layer is provided with a wear-resistant layer.

[0008] Preferably, the rear side of the detection sensor body is provided with a positioning mounting plate.

[0009] Preferably, the outer side of the three-dimensional coil is provided with a gold plating layer.

[0010] Preferably, the reinforcing layer is made of carbon fiber and is adhered to the outer surface of the sensor body.

[0011] Preferably, the wear-resistant layer comprises, from the inside out, a silicon carbide coating and a glass fiber braided layer.

[0012] Preferably, the glass fiber braided layer has a mesh size of 80 to 160 mesh.

[0013] Preferably, the silicon carbide coating is applied to the outer side of the glass fiber braided layer.

[0014] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0015] 1. By setting up a reinforcing layer, this utility model can enhance the external toughness and strength of the detection sensor body. By setting up a wear-resistant layer, with the assistance of the glass fiber braided layer and silicon carbide coating, the wear resistance and high temperature resistance of the detection sensor body surface can be further improved, which can better protect the detection sensor body.

[0016] 2. This utility model, through the setting of a low-temperature co-fired ceramic substrate and with the assistance of silver screen-printed coils, after sequentially stacking, isostatically pressing, and high-temperature sintering to form a three-dimensional coil, enables the multi-layer induction probe structure made of low-temperature co-fired ceramic as the substrate and silver as the coil material to withstand high temperatures, and has a large inductance and a small resistance. The no-load quality factor is greater than 100%, and the linear measurement range and sensitivity are high. This realizes that the array eddy current weld seam detection sensor has the advantages of wear resistance, high temperature resistance, and wide applicability. Attached Figure Description

[0017] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0018] Figure 2 This is a schematic diagram of the low-temperature co-fired ceramic substrate structure of this utility model;

[0019] Figure 3 This is a schematic diagram of the three-dimensional coil structure of this utility model;

[0020] Figure 4 This is a schematic diagram of the reinforcing layer structure of this utility model;

[0021] Figure 5 This is a schematic diagram of the wear-resistant layer structure of this utility model;

[0022] Figure 6 This is a physical image of the sensing probe of this utility model;

[0023] Figure 7 This is a schematic diagram of the top layer structure of the coil of this utility model under a microscope;

[0024] Figure 8 This is a cross-sectional view of the coil of this utility model under a microscope;

[0025] Figure 9 This is a diagram of the coil impedance characteristic testing device of this utility model;

[0026] Figure 10 This is a graph showing the variation of the coil inductance and resistance of this utility model with frequency;

[0027] Figure 11 This is a graph showing the variation of the coil impedance modulus and phase angle with frequency of this utility model.

[0028] In the figure: 1. Sensor body; 101. Sensing probe; 1011. Low temperature co-fired ceramic substrate; 1012. Silver screen-printed coil; 1013. 3D coil; 1014. Gold plating layer; 2. Positioning mounting plate; 3. Reinforcing layer; 4. Wear-resistant layer; 401. Silicon carbide coating; 402. Glass fiber braided layer. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0030] In the description of this utility model, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. In addition, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0031] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0032] The detection sensor body 1, sensing probe 101, low-temperature co-fired ceramic substrate 1011, silver screen-printed coil 1012, three-dimensional coil 1013, gold plating layer 1014, positioning mounting plate 2, reinforcing layer 3, wear-resistant layer 4, silicon carbide coating 401, and glass fiber braided layer 402 components in this application are all general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0033] Example 1

[0034] Please see Figures 1-11 As shown, this utility model provides a technical solution: a wear-resistant and high-temperature resistant array eddy current weld detection sensor, including a detection sensor body 1, and further comprising:

[0035] A sensing probe 101 is disposed on one side of the sensor body 1. Multiple low-temperature co-fired ceramic substrates 1011 are disposed on the inner side of the sensing probe 101. A silver screen-printed coil 1012 is disposed on the inner surface of the low-temperature co-fired ceramic substrates 1011. Multiple low-temperature co-fired ceramic substrates 1011 are stacked in sequence, isostatically pressed and sintered at high temperature to form a three-dimensional coil 1013.

[0036] An enhancement layer 3 is disposed on the outside of the sensor body 1, and a wear-resistant layer 4 is disposed on the outside of the enhancement layer 3.

[0037] The reinforcing layer 3 is made of carbon fiber and is adhered to the outer surface of the sensor body 1. The wear-resistant layer 4 includes a silicon carbide coating 401 and a glass fiber braided layer 402 from the inside to the outside. The glass fiber braided layer 402 has a mesh size of 80 to 160 mesh. The silicon carbide coating 401 is applied to the outer side of the glass fiber braided layer 402.

[0038] This technical solution: By setting the reinforcing layer 3, the external toughness and strength of the detection sensor body 1 can be enhanced. By setting the wear-resistant layer 4, with the assistance of the glass fiber braided layer 402 and the silicon carbide coating 401, the wear resistance and high temperature resistance of the surface of the detection sensor body 1 can be further improved, which can better protect the detection sensor body 1. By setting the low temperature co-fired ceramic substrate 1011, and with the assistance of the silver screen-printed coil 1012, after stacking, isostatic pressing and high temperature sintering in sequence to form a three-dimensional coil 1013, the multi-layer induction probe structure made of low temperature co-fired ceramic as the substrate and silver as the coil material can withstand high temperature, and has a large inductance and a small resistance. The no-load quality factor is greater than 30, and the linear measurement range and sensitivity are high. This realizes that the array eddy current weld detection sensor has the advantages of wear resistance, high temperature resistance and wide applicability.

[0039] Fabrication and Experimental Analysis of the Induction Probe

[0040] Au, Ag, Cu, and Pt are four common coil materials. Analysis of the impedance characteristics of the coils at 600℃ revealed that the inductances of the four coils are similar, while the Ag coil exhibits the lowest resistance and highest sensitivity. Using varying temperature as a boundary condition to analyze the structural reliability, in terms of manufacturing processes, Au and Ag can be directly sintered in air, while Cu must be sintered in nitrogen, increasing the manufacturing complexity. Therefore, considering all factors, Ag is the most suitable coil material.

[0041] Figure 6 This is a picture of the actual manufactured induction probe, which consists of a low-temperature co-fired ceramic substrate and a screen-printed silver coil. First, a screen template is made according to a pre-designed pattern. The required circuit pattern is created by drilling holes in a green ceramic sheet, filling it with silver paste, and screen printing. Then, multiple layers of green ceramic sheets are stacked in sequence, isostatically pressed, and sintered at high temperature (850℃) to form a three-dimensional probe coil structure.

[0042] Geometric parameters such as coil line width, spacing, and internal structure were tested using a tool microscope, such as... Figure 7 , Figure 8 As shown, the minimum width of the coil wire was measured to be 0.115 mm, and the maximum width was 0.126 mm, with a manufacturing error of less than 5%. This indicates good consistency in the coil wire diameter, accurate replication of the circuit pattern, high positional accuracy of each part relative to the reference, and good thickness uniformity.

[0043] Figure 9 This diagram shows a device for testing the impedance characteristics of an induction coil. The induction coil is fixed to one end of a displacement platform. The two electrodes of the coil are connected to an impedance analyzer via test clips and shielded wires. The impedance analyzer connects and communicates with a computer via a GPIG cable and interface. The start frequency, cutoff frequency, number of scan points, and impedance parameters to be measured are set in a pre-programmed LabVIEW program. The coil impedance is measured using the four-probe method, which reduces the influence of wiring resistance and contact resistance on the measurement results. During measurement, the LabVIEW program interface not only displays the real-time values ​​of the measured parameters but also plots the trend of the measured parameters with frequency, facilitating result analysis.

[0044] Within the range of 50 to 5 MHz, sweep frequency measurements were performed on the resistance R, inductance L, impedance mode Z, and phase angle φ of the induction coil under no-load conditions. Figure 10 , Figure 11As shown. Since the induction coil contains both inductance and resistance, all impedance characteristics undergo significant resonant changes, with the coil's self-resonant frequency at 1.8MHz. Below 1.8MHz, the coil's resistance and inductance increase with frequency, reaching their maximum values ​​near 1.8MHz. Correspondingly, the phase angle gradually increases and tends towards +90°, at which point the coil exhibits inductive characteristics. After reaching the resonant frequency, the inductance changes from its positive maximum value to a negative value, and the phase angle changes from +90° to -90°, at which point the sensor begins to exhibit capacitive characteristics. According to the basic principle of eddy current detection, the sensor can only operate within the frequency range where inductive characteristics are exhibited; therefore, the operating frequency must be lower than the self-resonant frequency.

[0045] Based on the simulation, the coil impedance values ​​are: R = 21.964Ω, L = 112μH, C = 62.5pF. quality factor of the coil at 1MHz The experimentally tested resonant frequency was lower than the calculated value because the cable's own capacitance, inductance, and parasitic capacitance were not considered in the calculation.

[0046] Example 2

[0047] Based on Embodiment 1, this utility model is as follows: Figures 1-5 As shown, a positioning mounting plate 2 is provided on the rear side of the detection sensor body 1.

[0048] This technical solution: By setting the positioning mounting plate 2, it is convenient to install the detection sensor body 1.

[0049] Example 3

[0050] Based on Embodiment 1, this utility model is as follows: Figures 1-5 As shown, a gold-plated layer 1014 is provided on the outer side of the three-dimensional coil 1013.

[0051] This technical solution effectively prevents the three-dimensional coil 1013 from oxidizing at high temperatures by setting the gold plating layer 1014, thus improving its service life.

[0052] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit the scope of protection of this utility model. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the essence and scope of the technical solutions of this utility model.

Claims

1. A wear-resistant and high-temperature resistant array eddy current weld seam detection sensor, comprising a detection sensor body (1), characterized in that, Also includes: A sensing probe (101) is disposed on one side of the sensor body (1). Multiple low-temperature co-fired ceramic substrates (1011) are disposed on the inner side of the sensing probe (101). A silver screen-printed coil (1012) is disposed on the inner surface of the low-temperature co-fired ceramic substrates (1011). Multiple low-temperature co-fired ceramic substrates (1011) are stacked in sequence, isostatically pressed and sintered at high temperature to form a three-dimensional coil (1013). An enhancement layer (3) is disposed on the outside of the sensor body (1), and a wear-resistant layer (4) is disposed on the outside of the enhancement layer (3).

2. The wear-resistant and high-temperature-resistant array eddy current weld seam detection sensor according to claim 1, characterized in that: A positioning mounting plate (2) is provided on the rear side of the detection sensor body (1).

3. The wear-resistant and high-temperature-resistant array eddy current weld seam detection sensor according to claim 1, characterized in that: The outer side of the three-dimensional coil (1013) is provided with a gold-plated layer (1014).

4. The wear-resistant and high-temperature-resistant array eddy current weld detection sensor according to claim 1, characterized in that: The reinforcing layer (3) is made of carbon fiber and is adhered to the outer surface of the sensor body (1).

5. The wear-resistant and high-temperature-resistant array eddy current weld seam detection sensor according to claim 1, characterized in that: The wear-resistant layer (4) consists of a silicon carbide coating (401) and a glass fiber braided layer (402) from the inside out.

6. The wear-resistant and high-temperature-resistant array eddy current weld seam detection sensor according to claim 5, characterized in that: The glass fiber braided layer (402) has a mesh size of 80 to 160 mesh.

7. The wear-resistant and high-temperature-resistant array eddy current weld seam detection sensor according to claim 5, characterized in that: The silicon carbide coating (401) is applied to the outside of the glass fiber braided layer (402).

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