Flexible Magnetostrictive Sensor Probe for Wire Rope Inspection
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Solution Overview
Problem
Existing non-destructive testing methods for longitudinal cylindrical structures, such as wire ropes and anchor rods, face challenges with high costs due to heavy and expensive DC biasing magnets, and limitations in inspecting non-ferrous materials or those with poor magnetostrictive properties, requiring complex and costly modifications or additional materials.
Innovation Solution
A flexible, lightweight, and cost-effective magnetostrictive sensor probe assembly with a flexible strip of magnetostrictive material and a thin, bendable permanent magnet circuit, integrated with a flat flexible cable coil, allowing for efficient guided-wave inspection of curved surfaces without the need for heavy magnets, and adaptable to various materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If DC biasing magnets are used for magnetostrictive sensor inspection, then guided-wave generation and detection capability is achieved, but the system becomes heavy and expensive
Solution Approach 1:
The patent replaces the traditional mechanical DC biasing magnet system with an electromagnetic field generation approach using coil assemblies. Instead of using heavy permanent magnets to provide DC magnetic bias, the invention uses electrical current through coils to generate the necessary magnetic field for magnetostrictive wave generation and detection, significantly reducing probe weight while maintaining inspection capability
Solution Approach 2:
The invention changes the operational parameters from static DC magnetic bias (requiring heavy magnets) to dynamic electromagnetic field generation (using lightweight coils). This parameter change allows the system to achieve the same magnetostrictive effect without the weight penalty of permanent DC biasing magnets
2Reliability
If DC biasing magnets are used for magnetostrictive sensor inspection, then guided-wave generation and detection capability is achieved, but the system cost increases significantly
Solution Approach 1:
The patent replaces expensive DC biasing magnets with cost-effective coil assemblies that generate electromagnetic fields. This substitution dramatically reduces material costs and manufacturing complexity while maintaining the essential function of magnetostrictive wave generation and detection
Solution Approach 2:
The invention uses relatively inexpensive coil assemblies that can be easily manufactured and replaced if needed, replacing the costly permanent magnet system. The coil-based approach allows for more economical probe construction and potential disposal or replacement without significant financial impact
3Adaptability or versatility
If traditional MsS method is used for non-ferrous materials or materials with poor magnetostrictive properties, then inspection capability is achieved, but complex and costly modifications are required
Solution Approach 1:
The patent creates a universal inspection system using electromagnetic coil assemblies that can inspect various materials including non-ferrous materials and materials with poor magnetostrictive properties. The electromagnetic field generation approach is material-agnostic, allowing the same basic probe design to work across different material types without complex modifications
Solution Approach 2:
The invention changes the inspection approach from magnet-based (material-dependent) to electromagnetic field-based (material-independent). This parameter change allows the system to adapt to different materials by adjusting electrical parameters rather than requiring physical modifications to the probe structure
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 economical, versatile, and efficient non-destructive testing of wire ropes, cables, and anchor rods by generating and detecting longitudinal guided waves, improving inspection capabilities and reducing costs, while being operable on a wide range of materials and surface curvatures.
Implementation Method 1
a flexible strip of magnetostrictive material that is positioned and/or adhered to the base of a generally flat, flexible, conductor coil assembly
Implementation Method 2
a thin and bendable permanent magnet circuit
Data Source
AI summary
An economical, flexible, magnetostrictive sensor (MsS) probe assembly for use on longitudinal cylindrical structures, for guided-wave, volumetric inspection of the structures is described. The paired flexible plate MsS probes each include a flexible strip of magnetostrictive material that is positioned and/or adhered to the base of a generally flat, flexible, conductor coil assembly, preferably with an elastomeric adhesive. The conductor coil assembly has a core composed of a thin flexible layer of metal and a thin bendable permanent magnet circuit. The flexible core is surrounded by a flat flexible cable (FFC) that is folded and looped over the layers of the core. The exposed conductors at the ends of the FFC are shifted from each other by one conductor spacing and joined together so that the parallel conductors in the FFC form a flat, flexible, continuous coil. The probe assemblies may preferably be utilized in pairs and conformed to match the curved contours of the cylindrical surface of the structure under investigation in a manner that is specifically tailored for wire rope, cable, and anchor rod type applications.