A portable magnetic particle inspection and verification device

Abstract

A portable magnetic particle inspection and verification device includes a flexible Rogowski coil sensor module, a signal integration and filtering module, an analog-to-digital conversion and processing module, a timer detection module, a display and human-machine interaction module, a data storage module, a power management module, and a communication module. The flexible Rogowski coil sensor module senses the rate of change of current in the measured conductor; the signal integration and filtering module converts the electrical signal into an analog voltage signal; the analog-to-digital conversion and processing module calculates the effective value and peak value of the current and generates current waveform data; the display and human-machine interaction module displays the current waveform, numerical value, and timing results; the data storage module stores the data and uploads it to a remote server via the communication module; and the power management module provides a stable power supply. This invention overcomes the shortcomings of existing technologies, solving the problems of poor portability, insufficient accuracy, and limited functionality in existing equipment, and achieves integrated high-precision current measurement and timing verification.

Description

Technical Field

[0001] This utility model relates to the field of testing equipment technology, specifically to a portable magnetic particle flaw detection and verification device. Background Technology

[0002] Magnetic particle inspection machines are widely used in aerospace, automotive, machinery manufacturing, and energy industries, and are essential equipment for detecting surface and near-surface cracks in ferromagnetic materials. The magnetizing current (including longitudinal and circumferential magnetizing current) of a magnetic particle inspection machine directly affects the inspection results. To ensure inspection quality, national standards (such as JJF1273-2011 "Specification for Calibration of Magnetic Particle Inspection Machines") and international standards (such as ASTM E1444-2022) require magnetic particle inspection machines to be calibrated regularly, especially for the precise measurement and verification of current values ​​and magnetization time.

[0003] Existing verification methods have the following technical shortcomings:

[0004] Traditional current measurement methods have obvious limitations: commonly used methods such as Hall sensors, current transformers or shunts have the following problems: (1) They have strict limitations on the structure of the conductor being measured and cannot be applied to large conductors or irregularly shaped conductors; (2) They are large and heavy and have poor portability; (3) They have insufficient ability to suppress stray magnetic fields in strong magnetic field environments, which affects the measurement accuracy.

[0005] Difficulty in handling high current measurement requirements: The circumferential magnetization current of magnetic particle flaw detectors can reach up to 9000A. Existing measuring equipment suffers from decreased accuracy and insufficient linearity when measuring high current.

[0006] Lack of integrated verification function: Most devices on the market can only detect current and cannot simultaneously and accurately verify the timer of the magnetic particle flaw detector. Utility Model Content

[0007] To address the shortcomings of existing technologies, this utility model provides a portable magnetic particle inspection and calibration device that overcomes the deficiencies of existing technologies. It is reasonably designed and solves the problems of poor portability, insufficient accuracy, and limited functionality of existing equipment, thereby achieving integrated high-precision current measurement and timing calibration.

[0008] To achieve the above objectives, this utility model provides the following technical solution:

[0009] A portable magnetic particle inspection and verification device includes a flexible Rogowski coil sensor module, a signal integration and filtering module, an analog-to-digital conversion and processing module, a timer detection module, a display and human-machine interaction module, a data storage module, a power management module, and a communication module.

[0010] The output of the flexible Rogowski coil sensor module is connected to the input of the signal integration and filtering module via an anti-interference shielded cable. The flexible Rogowski coil sensor module is used to surround the conductor being measured and sense the rate of change of current, and convert the sensed rate of change of current into an electrical signal, which is then transmitted to the signal integration and filtering module via the anti-interference shielded cable.

[0011] The output of the signal integration and filtering module is connected to the analog signal input of the analog-to-digital conversion and processing module. The signal integration and filtering module is used to integrate and filter the received electrical signal, convert it into an analog voltage signal proportional to the current amplitude, and input the processed analog voltage signal to the analog-to-digital conversion and processing module.

[0012] The timer detection module is used to receive the trigger signal from the analog-to-digital conversion and processing module. When the current value exceeds the first threshold, the timing starts, and when it falls below the second threshold, the timing stops.

[0013] The analog-to-digital conversion and processing module is used to digitize analog signals, calculate the effective value and peak value of current in real time, and generate current waveform data.

[0014] The display and human-computer interaction module is connected to the analog-to-digital conversion and processing module through a parallel interface, and is used to display the current waveform, value and timing results in real time.

[0015] The data storage module is connected to the data interface of the analog-to-digital conversion and processing module via a dual-channel SDIO bus, and is used to store test data and upload it to a remote server via the communication module.

[0016] The power management module provides a stable power supply to the flexible Rogowski coil sensor module, signal integration and filtering module, analog-to-digital conversion and processing module, timer detection module, display and human-machine interaction module, data storage module, and communication module.

[0017] Preferably, the flexible Rogowski coil sensor module includes a hollow coil winding, an insulating coating layer, and a magnetic self-locking buckle. The hollow coil winding is formed by winding single or multiple strands of enameled wire on a flexible insulating frame. The insulating coating layer is fixedly wrapped around the outer surface of the hollow coil winding. The magnetic self-locking buckle is disposed at both ends of the hollow coil winding for locking and fixing the conductor being measured.

[0018] Preferably, the signal integration and filtering module includes an integrating operational amplifier, an active low-pass filter, a zero-point drift compensation circuit, and a gain adjustment unit. The input terminal of the integrating operational amplifier is connected to the flexible Rogowski coil sensor module, and the output terminal of the integrating operational amplifier is connected to the active low-pass filter. The filtered signal is corrected by the zero-point drift compensation circuit and then adjusted to a standard analog voltage signal by the gain adjustment unit.

[0019] Preferably, the timer detection module includes a dual threshold comparator, a high-stability crystal oscillator time base unit, and a time counter unit. The input of the dual threshold comparator is connected to the analog-to-digital conversion and processing module, and outputs a start / stop trigger signal through a hysteresis comparator circuit. The high-stability crystal oscillator time base unit is used to provide a precise time reference, and the time counter unit is used to record the time interval from start to stop.

[0020] This invention provides a portable magnetic particle testing and calibration device with the following advantages: The high sensitivity and anti-interference design of the flexible Rogowski coil sensor module ensures accurate capture of current changes, enabling stable operation even in complex electromagnetic environments. The efficient processing of the signal integration and filtering module further enhances signal purity. The precise timing function of the timer detection module makes the measurement of magnetization period more accurate and reliable, providing an important reference for magnetic particle testing and calibration. The display and human-machine interaction module adopts an intuitive and easy-to-use interface design, allowing operators to easily set parameters and view data, greatly improving work efficiency. The data storage and communication module supports multiple storage and upload methods, ensuring the secure and convenient sharing of test data. In summary, this invention achieves high precision, high efficiency, and portability of the magnetic particle testing and calibration device through the coordinated work of its various modules. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in this utility model or the prior art, the accompanying drawings used in the description of this utility model or the prior art will be briefly introduced below.

[0022] Figure 1 Structural principle block diagram of this utility model;

[0023] Figure 2 The working principle and steps of this utility model are shown in the flowchart. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0025] Example 1, as Figure 1-2 As shown, a portable magnetic particle inspection and verification device includes a flexible Rogowski coil sensor module 1, a signal integration and filtering module 2, an analog-to-digital conversion and processing module 3, a timer detection module 4, a display and human-machine interaction module 5, a data storage module 6, a power management module 7, and a communication module 8.

[0026] The output of the flexible Rogowski coil sensor module 1 is connected to the input of the signal integration and filtering module 2 via an anti-interference shielded cable. The flexible Rogowski coil sensor module 1 is used to surround the conductor being measured and sense the rate of change of current (di / dt), converting the sensed rate of change of current into an electrical signal, which is then transmitted to the signal integration and filtering module 2 via the anti-interference shielded cable; specifically,

[0027] The flexible Rogowski coil sensor module 1 includes a hollow coil winding, an insulating coating layer, and magnetic self-locking clips. The hollow coil winding consists of 120-150 turns of single or multi-strand polyimide enameled copper wire uniformly wound on an insulating silicone skeleton, with a wire diameter of 0.2-0.5 mm and an inner diameter of 50-100 mm. The insulating coating layer is fixedly wrapped around the outer surface of the hollow coil winding. In this embodiment, the insulating coating layer is a silicone rubber composite insulating layer. The magnetic self-locking clips are located at both ends of the hollow coil winding for locking and fixing the conductor being measured. Furthermore, a double-layer electromagnetic shielding structure can be covered on the outer surface of the insulating coating layer. The double-layer electromagnetic shielding structure includes a copper foil shielding layer and a high-permeability alloy mesh. Nano-ferrite absorbing material is filled between the copper foil shielding layer and the insulating coating layer. The high-permeability alloy mesh covers the outside of the copper foil shielding layer, forming a composite shielding layer that effectively suppresses external electromagnetic interference and ensures signal transmission stability.

[0028] The output of the signal integration and filtering module 2 is connected to the analog signal input of the analog-to-digital conversion and processing module 3. The signal integration and filtering module 2 is used to convert the differential current signal (di / dt) output by the flexible Rogowski coil sensor module 1 into a voltage signal proportional to the current amplitude, and filter out high-frequency electromagnetic interference (especially switching noise >1kHz); and input the processed analog voltage signal to the analog-to-digital conversion and processing module 3.

[0029] Furthermore, the signal integration and filtering module 2 includes an integrating operational amplifier, an active low-pass filter, a zero-drift compensation circuit, and a gain adjustment unit. The input of the integrating operational amplifier is connected to the flexible Rogowski coil sensor module, and the output of the integrating operational amplifier is connected to the active low-pass filter. The filtered signal is corrected by the zero-drift compensation circuit and then adjusted to a standard analog voltage signal by the gain adjustment unit. Specifically, the integrating operational amplifier uses an ADA4522-2 chip and polypropylene film capacitors to form a high-performance integrating circuit, ensuring accurate integration of the differential current signal and achieving a full-range error of ≤±0.5% from 0 to 10000A. The active low-pass filter uses a Sallen-Key second-order topology with an adjustable cutoff frequency of 0.1 to 10Hz. The zero-drift compensation circuit uses an OP07 chip to effectively compensate for zero-drift caused by temperature changes, ensuring signal accuracy. The gain adjustment unit uses an adjustable gain circuit composed of precision resistors and potentiometers, which can appropriately amplify the signal as needed to adapt to different measurement ranges.

[0030] The timer detection module 4 is used to receive the trigger signal from the analog-to-digital conversion and processing module 3. When the current value exceeds the first threshold, the timing starts, and when it falls below the second threshold, the timing stops; thus, the time interval from the start to the end of magnetization can be accurately measured.

[0031] Furthermore, the timer detection module 4 includes a dual-threshold comparator, a high-stability crystal oscillator time base unit, and a time counter unit. The input of the dual-threshold comparator is connected to the analog-to-digital conversion and processing module 3, and outputs a start / stop trigger signal through a hysteresis comparator circuit. More specifically, the dual-threshold comparator includes an independent DA converter (MAX5216), which can achieve 0.1A step adjustment between the high threshold (300-1000A) and the low threshold (50-300A). The high-stability crystal oscillator time base unit uses an OCXO temperature-controlled crystal oscillator and is placed in a vacuum-insulated cavity, outputting a 1Hz reference clock; the time counter unit is used to record the time interval from start to stop.

[0032] The analog-to-digital conversion and processing module 3 is used to digitize analog signals, calculate the effective value and peak value of current in real time, and generate current waveform data. Specifically, the analog-to-digital conversion and processing module 3 includes a 16-bit high-speed ADC (ADS8588S) and an embedded MCU digital signal processor (DSP28335). The ADC converts analog voltage signals into digital signals, and the DSP performs data processing and effective value calculation, and generates a current waveform graph to display the current change trend in real time. At the same time, the algorithm module built into the DSP can perform spectrum analysis on the data to identify harmonic components in the current, ensuring the comprehensiveness and accuracy of the measurement results.

[0033] The display and human-machine interaction module 5 is connected to the frame buffer controller of the analog-to-digital conversion and processing module 3 via a shielded FPC cable, and is used to display current waveforms, values, and timing results in real time. Data transmission adopts a 16-bit RGB parallel bus + LVDS conversion architecture; touch signals are transmitted back to the MCU digital signal processor of the analog-to-digital conversion and processing module 3 via an I²C bus; the cable incorporates a double-layer electromagnetic shielding mesh and a π-type ferrite bead filter circuit.

[0034] The data storage module 6 is connected to the data interface of the analog-to-digital conversion and processing module 3 via a dual-channel SDIO bus. It is used to store test data and upload it to a remote server via the communication module 8. Specifically, the data storage module 6 includes an onboard eMMC chip and an expansion SD card slot. The main channel uses an eMMC 5.1 chip to achieve real-time data caching. The expansion channel supports hot-swappable SD cards to store historical data. The communication module 8 includes a USB-C 3.1 isolation circuit and a Wi-Fi 6 / Bluetooth 5.2 dual-mode wireless module.

[0035] The power management module 7 provides a stable power supply for the flexible Rogowski coil sensor module 1, the signal integration and filtering module 2, the analog-to-digital conversion and processing module 3, the timer detection module 4, the display and human-machine interaction module 5, the data storage module 6, and the communication module 8.

[0036] Working principle:

[0037] First, the flexible Rogowski coil sensor module 1 is wrapped around the current conductor of the magnetic particle flaw detector under test; and mechanically fixed by magnetic self-locking buckles; then, the current detection mode is selected on the display and human-machine interaction module 5; the current range (e.g., low (0-3000A), medium (3000-7000A), high (7000-10000A)) and the sampling time reference are set.

[0038] The device is then started. The flexible Rogowski coil sensor module 1 senses current changes in real time and converts the sensed current change rate into an electrical signal, which is then transmitted to the signal integration and filtering module 2 via an anti-interference shielded cable. The signal integration and filtering module 2 converts the di / dt signal into a voltage signal proportional to the current amplitude and filters out high-frequency electromagnetic interference. The analog-to-digital conversion and processing module 3 performs high-precision sampling, and the current RMS value, peak value, and waveform curve are displayed on the display and human-machine interface module 5. When the current value reaches the trigger threshold, the timer detection module 4 prepares to operate. When the current value rises above the first threshold, magnetization begins, and the timer detection module 4 starts timing. When the current value drops to the second threshold, magnetization ends, the timer stops, and the magnetization period is recorded. All data is stored in real time in the data storage module 6 and uploaded to the server via a communication module 8 (USB-C or wireless module) for subsequent analysis. The recorded data includes key parameters such as the current waveform, RMS value, peak value, and magnetization period. Through the display and human-machine interaction module 5, operators can intuitively view real-time current data and magnetization cycle, thereby determining whether the magnetic particle flaw detector is working properly.

[0039] This invention, through the high sensitivity and anti-interference design of the flexible Rogowski coil sensor module, ensures accurate capture of current changes and stable operation even in complex electromagnetic environments. The efficient processing of the signal integration and filtering module further enhances signal purity, laying a solid foundation for subsequent digital processing. The precise timing function of the timer detection module makes the measurement of magnetization period more accurate and reliable, providing an important reference for magnetic particle inspection verification. The display and human-machine interaction module adopts an intuitive and easy-to-use interface design, allowing operators to easily set parameters and view data, greatly improving work efficiency. The data storage and communication module supports multiple storage and upload methods, ensuring the secure and convenient sharing of test data. In summary, this invention, through the collaborative work of its modules, achieves high precision, high efficiency, and portability of the magnetic particle inspection verification device, providing strong support for the application of magnetic particle inspection technology.

[0040] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A portable magnetic particle inspection verification device, characterized by: It includes a flexible Rogowski coil sensor module (1), a signal integration and filtering module (2), an analog-to-digital conversion and processing module (3), a timer detection module (4), a display and human-computer interaction module (5), a data storage module (6), a power management module (7), and a communication module (8). The output end of the flexible Rogowski coil sensor module (1) is connected to the input end of the signal integration and filtering module (2) through an anti-interference shielded cable. The flexible Rogowski coil sensor module (1) is used to surround the conductor under test and sense the rate of change of current, and convert the sensed rate of change of current into an electrical signal, which is then transmitted to the signal integration and filtering module (2) through an anti-interference shielded cable. The output of the signal integration and filtering module (2) is connected to the analog signal input of the analog-to-digital conversion and processing module (3). The signal integration and filtering module (2) is used to integrate and filter the received electrical signal and convert it into an analog voltage signal that is proportional to the current amplitude. The processed analog voltage signal is then input to the analog-to-digital conversion and processing module (3). The timer detection module (4) is used to receive the trigger signal from the analog-to-digital conversion and processing module (3). When the current value exceeds the first threshold, the timing starts, and when it is below the second threshold, the timing stops. The analog-to-digital conversion and processing module (3) is used to realize the digitization of analog signals, calculate the effective value and peak value of current in real time, and generate current waveform data; The display and human-computer interaction module (5) is connected to the analog-to-digital conversion and processing module (3) through a parallel interface, and is used to display the current waveform, value and timing results in real time; The data storage module (6) is connected to the data interface of the analog-to-digital conversion and processing module (3) via a dual-channel SDIO bus, and is used to store test data and upload it to a remote server via the communication module (8); The power management module (7) provides a stable power supply to the flexible Rogowski coil sensor module (1), signal integration and filtering module (2), analog-to-digital conversion and processing module (3), timer detection module (4), display and human-computer interaction module (5), data storage module (6) and communication module (8).

2. The portable magnetic particle inspection verification device of claim 1, wherein: The flexible Rogowski coil sensor module (1) includes a hollow coil winding, an insulating coating layer, and a magnetic self-locking buckle. The hollow coil winding is made of single or multiple strands of enameled wire wound on a flexible insulating frame. The insulating coating layer is fixedly wrapped around the outer surface of the hollow coil winding. The magnetic self-locking buckle is set at both ends of the hollow coil winding and is used to lock and fix the conductor being measured.

3. The portable magnetic particle inspection verification device of claim 1, wherein: The signal integration and filtering module (2) includes an integrating operational amplifier, an active low-pass filter, a zero-point drift compensation circuit, and a gain adjustment unit. The input terminal of the integrating operational amplifier is connected to the flexible Rogowski coil sensor module, and the output terminal of the integrating operational amplifier is connected to the active low-pass filter. The filtered signal is corrected by the zero-point drift compensation circuit and then adjusted to a standard analog voltage signal by the gain adjustment unit.

4. The portable magnetic particle inspection and verification device according to claim 1, characterized in that: The timer detection module (4) includes a dual threshold comparator, a high-stability crystal oscillator time base unit and a time counter unit. The input terminal of the dual threshold comparator is connected to the analog-to-digital conversion and processing module (3), and outputs start and stop trigger signals through a hysteresis comparator circuit. The high-stability crystal oscillator time base unit is used to provide a precise time reference, and the time counter unit is used to record the time interval from start to stop.

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