Inductive Crack Removal in Hot Metal Making
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Solution Overview
Problem
Current methods for removing cracks in metallic materials during the metal making process are inefficient, as they require cooling the material and can only detect visible surface cracks, leading to incomplete removal of cracks.
Innovation Solution
A method and arrangement for removing cracks in metallic materials during the metal making process, which involves using a crack detecting unit with inductive measurement to determine the presence and depth of cracks, and a crack removal unit with an ejector that varies the intensity of the carving means based on the crack depth, allowing for efficient crack removal without cooling the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical detection methods are used to detect cracks, then large visible cracks can be detected, but only surface cracks are detected and colour variations may be misinterpreted as cracks
Solution Approach 1:
The patent replaces optical detection methods with inductive measurement using a crack detecting unit that generates electromagnetic fields. This substitution enables detection of cracks beneath the surface by measuring changes in electromagnetic field properties, thereby obtaining both detection accuracy and crack depth information simultaneously.
Solution Approach 2:
The patent changes the detection parameter from optical properties (light reflection, colour) to electromagnetic properties (inductance, impedance). By measuring electromagnetic field changes caused by cracks, the system can detect both surface and subsurface cracks while obtaining depth information through analysis of field penetration characteristics.
2Reliability
If crack removal is performed by grinding or melting after cooling the metal object, then cracks can be removed, but the process requires cooling for several days and is time-consuming
Solution Approach 1:
The patent performs crack detection and removal during the metal making process while the material is still hot, before cooling is required. The crack removing unit is positioned to receive hot metallic material directly from the casting process, enabling crack removal to be performed as a preliminary action before the material undergoes subsequent cooling and processing steps.
Solution Approach 2:
The patent changes the operating temperature parameter from room temperature (after cooling) to high temperature (during casting). By performing crack removal at high temperature, the process eliminates the need for prolonged cooling periods, significantly reducing production time while maintaining crack removal effectiveness.
3Ease of manufacture
If a fixed intensity of carving means is used for crack removal, then the process is simple, but excessive or insufficient material removal occurs
Solution Approach 1:
The patent makes the carving means intensity dynamic by varying it based on detected crack depth. The crack removing unit adjusts the intensity of the carving means (e.g., flame, water jet) in real-time according to the depth information obtained from inductive measurement, ensuring precise material removal without excessive or insufficient processing.
Solution Approach 2:
The patent implements a feedback control system where the crack detecting unit provides real-time depth information to the crack removing unit. This feedback loop enables automatic adjustment of carving means intensity to match the actual crack depth, achieving precise crack removal while maintaining process simplicity through automated control.
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 solution enables efficient crack removal during the metal making process, ensuring that cracks are removed to the appropriate depth without excessive material removal, and can detect and remove cracks both on the surface and beneath it, improving the quality of the metallic material.
Implementation Method 1
determining the presence of a crack and its crack depth during the metal making process by a crack detecting unit utilizing inductive measurement
Data Source
AI summary
A method of removing a crack in a metallic material during a metal making process. The method including: determining the presence of a crack and its crack depth during the metal making process by a crack detecting unit utilizing inductive measurement, sending a crack detection signal and crack depth to a crack removal unit arranged on known distance from the crack detecting unit, the crack removal unit including an ejector configured to eject a carving means, and to vary the intensity of the ejected carving means, removing the detected crack by activating the ejector based on the crack detection signal with an intensity of the ejected carving means based at least on the crack depth.