Cylindrical Magnetic Sensor Array for Small-Bore Pipe Crack Detection
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Solution Overview
Problem
Conventional crack detection apparatuses for small-bore piping systems face challenges in detecting small cracks and estimating crack size due to large sensor sizes and the need for circular rotation, which slows down measurement processes.
Innovation Solution
A crack detection apparatus and method utilizing a cylindrical sensor unit with a matrix of magnetic sensors and a bobbin coil, applying direct current and alternating current to detect magnetic-field distributions within the piping system, eliminating the need for circular rotation and enhancing spatial resolution and detection speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pickup coil is used for crack detection, then the sensor can be inserted into the piping system, but the large sensor size makes it difficult to detect small cracks and estimate crack shape
Solution Approach 1:
The sensor unit is divided into multiple magnetic sensors arranged in a matrix pattern (e.g., 4x4 or 5x5 array) on the cylindrical surface. This segmentation allows the system to achieve high measurement precision for small crack detection while maintaining a compact overall sensor structure that can be inserted into small-bore piping systems.
Solution Approach 2:
The magnetic sensors are arranged in a two-dimensional matrix on the cylindrical surface of the sensor unit, transitioning from one-dimensional linear arrays to two-dimensional spatial distribution. This dimensional change enables simultaneous measurement of magnetic field distributions in multiple directions, improving crack shape estimation and detection precision without increasing the overall sensor insertion diameter.
2Measurement precision
If a pancake coil is used for crack detection, then small cracks and their shape can be measured, but a scanner is required and measurement time is prolonged
Solution Approach 1:
Multiple magnetic sensors are merged into a single cylindrical sensor unit that can be inserted into the piping system as one component. This integration eliminates the need for external scanners and mechanical rotation mechanisms, allowing simultaneous measurement of magnetic field distributions across the entire sensor surface, thereby significantly reducing measurement time while maintaining high precision.
Solution Approach 2:
The mechanical scanning system (scanner with rotation mechanism) is replaced by an electronic sensor array system. Instead of mechanically moving a single sensor or coil around the pipe, multiple magnetic sensors are statically arranged in a matrix on the cylindrical surface, enabling parallel measurement of magnetic field distributions without mechanical movement, thus eliminating scanner requirements and reducing measurement time.
3Measurement precision
If a pancake coil is used for crack detection, then crack shape and size can be measured, but the sensor size is limited and cannot be reduced further
Solution Approach 1:
The sensor configuration transitions from a two-dimensional pancake coil structure to a three-dimensional cylindrical arrangement with magnetic sensors distributed on the curved surface. This dimensional change allows the sensor to maintain compact size while providing omnidirectional measurement capability for crack shape and size detection, effectively utilizing the radial and axial dimensions of the cylindrical geometry.
Solution Approach 2:
The sensor unit is segmented into multiple discrete magnetic sensors arranged in a matrix on the cylindrical surface, allowing each sensor to be small in size while the collective array provides comprehensive measurement coverage. This segmentation enables high-resolution crack shape measurement without requiring a large overall sensor diameter, making the system suitable for small-bore piping applications.
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
The apparatus achieves improved spatial resolution and faster crack detection in small-bore piping systems by using a cylindrical sensor unit with magnetic sensors and a bobbin coil, allowing for precise localization and measurement of crack distributions without requiring scanners or extensive rotation.
Implementation Method 1
applying alternating current (AC) power to a bobbin coil to thereby generate a magnetic field
Implementation Method 2
the sensor unit detects a distribution of a magnetic-field attributable to the crack in the small-bore piping system
Data Source
AI summary
Disclosed herein are an apparatus and method for detecting a crack in a small-bore piping system. The apparatus includes a sensor unit, a bobbin coil, a power supply unit, and a signal reception unit. The sensor unit is configured such that a plurality of magnetic sensors is arranged thereon and formed to be cylindrical. The bobbin coil is wound around the outside surface of the sensor unit. The power supply unit applies direct current (DC) power to the sensor unit and alternating current (AC) power to the bobbin coil. The signal reception unit quantifies a signal from the sensor unit. The sensor unit detects the distribution of a magnetic-field attributable to the crack in the small-bore piping system based on the AC power applied to the bobbin coil.