Double-Row Magnetic Sensor Probe for Steel Defect Quantification
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Solution Overview
Problem
Existing nondestructive testing methods for steel defects suffer from low detection sensitivity and low three-dimensional inversion accuracy, making it difficult to effectively identify and quantify defects in steel equipment.
Innovation Solution
A device and method utilizing internal and external magnetic perturbation, comprising a magnetizer, a double-row magnetic sensor probe, a master controller, and a host computer, which generates and analyzes magnetic field regions to collect and process data for defect quantification, improving detection sensitivity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional nondestructive testing methods are used, then the testing process is simple, but the detection sensitivity and three-dimensional inversion accuracy are low
Solution Approach 1:
The magnetic sensor probe is divided into a double-row array configuration, with sensors arranged in two parallel rows. This segmentation allows the system to capture magnetic perturbation data from multiple spatial positions simultaneously, improving detection sensitivity and enabling three-dimensional defect reconstruction through coordinated measurement of internal and external magnetic perturbations
Solution Approach 2:
The patent transitions from conventional single-point or single-line measurement to a two-dimensional array measurement system. The double-row magnetic sensor probe creates a planar measurement grid that captures magnetic field perturbations across a broader spatial domain, enabling three-dimensional inversion of defect characteristics from two-dimensional measurement data
2Measurement precision
If conventional nondestructive testing methods are used, then the device structure is simple, but the three-dimensional inversion accuracy is low
Solution Approach 1:
The magnetic sensor probe is segmented into two distinct rows of sensors, each row capturing magnetic perturbation data from different spatial locations. This segmented arrangement provides multi-position measurement capability that enhances the accuracy of three-dimensional defect inversion by supplying more comprehensive spatial information
Solution Approach 2:
The double-row magnetic sensor probe serves multiple functions: it detects internal magnetic perturbations, detects external magnetic perturbations, and enables three-dimensional defect reconstruction. This multi-functional design achieves high measurement precision without requiring multiple separate testing systems
3Measurement precision
If high-precision defect detection is implemented, then the detection accuracy improves, but the energy consumption increases
Solution Approach 1:
The system utilizes the steel sample's own magnetic properties and the naturally induced magnetic perturbations from defects as the measurement signal source. The defect itself generates the magnetic perturbation that is detected by the sensors, eliminating the need for complex external excitation systems and reducing energy consumption while maintaining high detection accuracy
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 solution enables accurate omnidirectional defect detection and quantification, enhancing the sensitivity and three-dimensional inversion accuracy of defect evaluation in steel equipment, with a simple structure and low energy consumption.
Implementation Method 1
a magnetizer comprising a magnetization source and a magnet yoke, arranged on a surface of a sample, and configured to generate two types of typical magnetic field regions applied to testing based on internal and external magnetic perturbation
Implementation Method 2
a double-row magnetic sensor probe, configured to collect internal and external magnetic perturbation data
Data Source
AI summary
A device and a method for testing a steel defect based on internal and external magnetic perturbation. The device includes: a magnetizer comprising a magnetization source and a magnet yoke, arranged on a surface of a sample, and configured to generate two types of typical magnetic field regions applied to testing based on internal and external magnetic perturbation; a double-row magnetic sensor probe, configured to collect internal and external magnetic perturbation data; a master controller, configured to perform pre-processing on the internal and external magnetic perturbation data, and store the pre-processed data; scanner wheels, configured to generate a sampling trigger pulse during scanning to enable the master controller to receive the internal and external magnetic perturbation data from the probes; and a host computer, configured to analyze the pre-processed data uploaded by the master controller to obtain a defect quantitative result.