Amorphous Magnetic Sensor Array for Minute Foreign Object Detection
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Solution Overview
Problem
Conventional magnetic body detecting devices face challenges in detecting minute magnetic bodies due to large sensor sizes and limited sensitivity, especially when the relative position and orientation of the magnetic body are unspecific, leading to missed detections.
Innovation Solution
The use of multiple amorphous material-based magneto-sensitive bodies with sensitive axes oriented in different directions to enhance detection sensitivity and avoid magnetic interference, allowing for reliable detection of minute magnetic bodies regardless of their position and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single large magnetic core is used in a fluxgate type magnetic detecting element, then the sensor structure is simple and easy to manufacture, but the sensor size becomes large and the distance between adjacent sensors increases, causing minute magnetic bodies positioned between sensors to be undetected
Solution Approach 1:
The patent divides a single large magnetic core into multiple small magnetic cores arranged in an array. Each small magnetic core functions as an independent sensing element, enabling the sensor to detect minute magnetic bodies in different positions simultaneously. This segmentation reduces the volume of each individual sensor while maintaining comprehensive detection coverage through the array configuration.
2Device complexity
If a single magnetic core with fixed orientation is used, then the sensor structure is simple, but detection sensitivity depends on the relative position and orientation of the metal piece, leading to missed detections when the metal piece is at low sensitivity positions
Solution Approach 1:
The patent assigns different orientation directions to different small magnetic cores in the array. Each magnetic core is oriented to detect magnetic pieces at specific positions and angles. This local quality differentiation ensures that regardless of the position and orientation of a metal piece, at least one magnetic core in the array will be optimally oriented to detect it, thereby improving detection reliability without requiring a single complex sensor configuration.
3Area of stationary object
If adjacent sensors are positioned far apart due to large sensor size, then each sensor has sufficient space, but minute magnetic bodies positioned between adjacent sensors cannot be detected
Solution Approach 1:
By segmenting the sensing function across multiple small magnetic cores arranged in a dense array, the patent achieves fine spatial sampling. The small size of each magnetic core allows them to be positioned closely together, creating overlapping detection zones that ensure minute magnetic bodies anywhere in the inspection area are detected by at least one sensor, thereby improving measurement precision while maintaining adequate spacing for practical deployment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables precise and reliable detection of foreign substances by processing signals from multiple sensors, ensuring comprehensive coverage and high sensitivity, reducing the likelihood of missed detections and improving detection accuracy.
Implementation Method 1
outputs a voltage corresponding to a local magnetic field generated by a magnetized minute magnetic body positioned around the magneto-sensitive body
Implementation Method 2
When an electrical pulse current or an alternate current is applied to a magneto-sensitive body of an amorphous material, outputs a voltage corresponding to a local magnetic field
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3(a)~3(b)
AI summary
[Object] To enable reliable detection of a minute magnetic body and enable omission-free detection with respect to detection of foreign substances of a minute magnetic body mixed at a state where positions and orientations in an inspected object are unspecific. [Solution Means] A minute magnetic body detecting sensor includes a magnetic impedance element 1, with two magneto-sensitive bodies 11 and 12 disposed in substantially two-dimensional directions such that an angle formed by respective sensitive axes s is substantially 90 degrees, and a signal processing device 2, including a signal processing circuit 20, processing and amplifying damped oscillating voltages output by the two magneto-sensitive bodies 11 and 12 that detected a local magnetic field due to a minute magnetic body that is a foreign substance, two square operating elements 21, squaring output signals m1 and m2, an adder 22, adding the squared signals m12 and m22, and a square root operating element 23, performing square root computation on the addition output and outputting a square root output ms, and enables high-precision detection of the existence or non-existence of a minute magnetic body without detection overlooking.