Eddy Current Probe for Contactless Casting Mould Metal Detection
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Solution Overview
Problem
Existing methods for detecting metal flow in casting moulds, such as physical contact probes and capacitance/inductance sensors, face challenges like maintenance costs, equipment integrity issues, and signal interference, particularly in closed moulds and counter gravity systems.
Innovation Solution
The use of eddy current probe assemblies positioned outside the casting mould to generate a primary magnetic field that passes through non-conductive mould material, detecting secondary magnetic fields induced in the metal and adjusting the filling rate based on these signals, without physical contact and using non-conductive mould materials like sand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If metal probes are used to physically contact the liquid metal for measuring filling rate, then the filling rate can be measured, but the probes require periodic cleaning or replacement due to build-up material and binder combustion, increasing maintenance activities and costs
Solution Approach 1:
The patent replaces mechanical contact probes with electromagnetic sensors (capacitive or inductive sensors) that measure filling rate without physical contact with the liquid metal. This substitution eliminates the build-up of material and binder combustion on the probe surface, thereby reducing maintenance activities and costs while maintaining measurement precision.
2Measurement precision
If metal probes are used to measure filling rate by closing an electrical circuit, then the filling rate can be detected, but electrical insulation of mould and filling equipment and electrical grounding of sensor must be taken into account, increasing system complexity
Solution Approach 1:
The patent replaces electrical contact-based detection with electromagnetic field-based sensors that do not require closing electrical circuits through the mould. This eliminates the need for electrical insulation of the mould and filling equipment, as well as grounding requirements, thereby reducing system complexity.
3Reliability
If capacitance or inductance sensors are used to detect liquid metal proximity, then the filling rate can be measured without contact, but the sensor must be in contact with the mould, increasing the risk of preserving sensor integrity and signal quality
Solution Approach 1:
The patent introduces a non-conductive mould as an intermediary between the electromagnetic sensor and the liquid metal. The sensor is positioned to detect changes in the electromagnetic field caused by the proximity of liquid metal through the non-conductive mould, eliminating direct contact while maintaining measurement reliability and protecting sensor integrity.
4Measurement precision
If capacitance or inductance sensors are used for detecting liquid metal, then the filling rate can be measured, but the sensor needs to be calibrated before each casting, slowing down the manufacturing process
Solution Approach 1:
The patent employs electromagnetic sensors with stable characteristics that do not require recalibration before each casting operation. The sensors maintain consistent performance throughout the manufacturing process, eliminating calibration steps and thereby increasing productivity without compromising measurement precision.
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 approach enables reliable, contactless metal detection with reduced maintenance costs and improved signal integrity, allowing for real-time adjustments of the filling rate and enhanced casting process quality.
Implementation Method 1
exciting at least one eddy current probe assembly of the plurality of eddy current probes such that each of the at least one eddy current probe assembly generates a primary magnetic field
Implementation Method 2
providing at each of the at least one eddy current probe assemblies a signal indicative of a secondary magnetic field detected by the respective eddy current probe assembly, the secondary magnetic field caused by eddy currents induced in metal in the inner area
Data Source
Figure 1a~1c
Figure 2
Figure 3a
AI summary
It is inter alia disclosed to use of one or more eddy current probe assemblies for detecting metal in an inner area of a casting mould during a casting process, wherein each of the one or more eddy current probe assemblies is configured to generate a primary magnetic field 115 passing through non-conductive mould material 140, 340, 530 of the casting mould to the inner area 145, 535 of the casting mould and to provide a signal indicative of a detected secondary magnetic 128, 128' field caused by eddy currents 125, 125' induced in metal 150, 350.