Cross-Coil Module Assembly for Automated Eddy Current Probes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of cross coils for eddy current testing is difficult to automate, leading to increased costs and prolonged manufacturing periods, especially for array probes requiring multiple cross coils.
Innovation Solution
A coil module design featuring a cross coil with first and second coils of annular shapes centered on intersecting axis lines, housed in a case with dedicated insertion points, and an array probe with an elastically deformable holding member, allowing for automated assembly and flexible scanning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a winding frame method is used to manufacture cross coils, then the structural integrity of the coil is improved, but the manufacturing complexity and time increase significantly
Solution Approach 1:
The cross coil is divided into two separate annular coils (first coil and second coil) that are manufactured independently and then assembled together. This segmentation allows each coil to be manufactured separately using automated winding processes, eliminating the need for complex alternating winding operations while maintaining the cross coil's structural integrity through precise positioning in the case.
Solution Approach 2:
The first coil and second coil are manufactured separately in advance before assembly. This preliminary action allows for automated manufacturing of each coil component using simple winding processes, and the final cross coil structure is formed by assembling the pre-manufactured components with precise positioning features in the case.
2Manufacturing precision
If manual alternating winding is used to create cross coils, then the coil configuration precision is improved, but the manufacturing period increases
Solution Approach 1:
The cross coil configuration is achieved by assembling two separately manufactured annular coils at right angles, rather than through complex alternating winding. This segmentation enables automated manufacturing of each coil while maintaining precise configuration through the case's positioning structure, significantly improving manufacturing speed without sacrificing precision.
Solution Approach 2:
The case serves as an intermediary structure that precisely positions and固定 the first coil and second coil at their correct orientations. This mediator ensures the required configuration precision while allowing the coils to be manufactured separately using automated processes, resolving the conflict between precision and productivity.
3Area of stationary object
If multiple cross coils are manufactured for array probes, then the detection coverage is improved, but the total manufacturing time increases
Solution Approach 1:
Each cross coil in the array probe is constructed from independently manufacturable first and second coils that can be produced using automated processes. This segmentation allows for rapid production of multiple cross coils, enabling array probes with extensive detection coverage to be manufactured without proportionally increasing total manufacturing time.
Solution Approach 2:
The invention changes the manufacturing parameter from manual alternating winding to automated separate coil winding followed by assembly. This parameter change enables rapid production of multiple cross coils for array probes, significantly reducing the total manufacturing time while maintaining the required detection coverage area.
4Productivity
If automated assembly is implemented for coil modules, then the productivity is improved, but the assembly precision requirements increase
Solution Approach 1:
The case is prepared in advance with built-in positioning features including insertion grooves and positioning protrusions. This preliminary action ensures that when automated assembly occurs, the first coil and second coil can be quickly and accurately positioned without requiring complex real-time precision control, thus improving productivity while maintaining assembly precision.
Solution Approach 2:
The case acts as a precision intermediary structure with integrated positioning features that guide the assembly of the first coil and second coil. This mediator translates the requirement for high assembly precision into simple geometric constraints that are easy to implement with automated assembly equipment, resolving the conflict between productivity and precision requirements.
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
Enables low-cost and rapid production of coil modules and array probes, enhancing detection accuracy and efficiency by reducing manufacturing time and noise, and improving conformance to curved surfaces.
Implementation Method 1
an excitation coil that generates an eddy current from an inner surface to an outer surface of a pipe
Implementation Method 2
a detection coil that detects a disturbance of the eddy current generated at a defective part of the pipe
Implementation Method 3
a holding member that supports the plurality of coil modules and is formed of an elastically deformable material
Data Source
AI summary
A coil module includes: a cross coil that includes a first coil having an annular shape centered on a first axis line, and a second coil having an annular shape centered on a second axis line intersecting the first axis line and covering a part of an outer peripheral side of the first coil; and a case that includes a first insertion point extending in a first axis line direction and into which the first coil is inserted and a second insertion point extending in a second axis line direction and into which the second coil is inserted.