Magnetic Sensor Calibration for Steel Sheet Inspection Accuracy
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Solution Overview
Problem
Existing inspection devices for steel sheets face challenges in maintaining consistent sensitivity among multiple magnetic sensors due to temperature and temporal variations, leading to measurement inaccuracies, and current calibration methods are time-consuming and disruptive to manufacturing processes.
Innovation Solution
A sensitivity calibration method and device that utilizes off-line and on-line calibration processes to adjust and maintain the sensitivity of magnetic sensors, using a standardized reference signal to align output values and correct for variations, allowing for continuous manufacturing without halting the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual sensitivity adjustment is performed for each magnetic sensor using a standard sample, then measurement accuracy is improved, but calibration time and labor increase significantly
Solution Approach 1:
The patent divides the calibration process into two distinct phases: an offline calibration phase where each sensor is individually adjusted using a standard sample, and an online calibration phase where sensors are calibrated simultaneously during production. This segmentation allows the time-consuming individual adjustment to be performed separately from production operations.
Solution Approach 2:
The patent performs preliminary sensitivity adjustment of each magnetic sensor individually using a standard sample before the actual production run. This preliminary calibration ensures each sensor starts with accurate sensitivity, and the results are stored for use during online calibration operations.
2Loss of time
If multiple sensors are calibrated simultaneously using a single standard sample, then calibration time is reduced, but measurement accuracy deteriorates due to variations within the standard sample
Solution Approach 1:
The patent segments the calibration process into individual sensor calibration using a standard sample, followed by group calibration during production. This ensures each sensor is individually calibrated for accuracy, then calibrated together during normal operations to maintain consistency.
Solution Approach 2:
The patent implements feedback by continuously monitoring sensor output during production and comparing it against reference values. When variations are detected, the system automatically adjusts sensor sensitivity to maintain measurement accuracy throughout the production process.
3Productivity
If sensitivity adjustment is performed during production operation, then manufacturing efficiency is maintained, but measurement accuracy may be affected by production variations
Solution Approach 1:
The patent performs preliminary sensitivity adjustment of each magnetic sensor individually using a standard sample before the actual production run. This preliminary calibration ensures each sensor starts with accurate sensitivity, and the results are stored for use during online calibration operations.
Solution Approach 2:
The patent implements feedback by continuously monitoring sensor output during production and comparing it against reference values. When variations are detected, the system automatically adjusts sensor sensitivity to maintain measurement accuracy throughout the production process.
4Measurement precision
If manual observation of output waveform is used for sensitivity adjustment, then measurement accuracy is improved, but operational complexity and labor increase
Solution Approach 1:
The patent implements self-service calibration where the system automatically adjusts sensor sensitivity based on predefined criteria and stored reference values. The calibration process requires minimal manual intervention, with the system performing adjustments autonomously during production operations.
Solution Approach 2:
The patent implements feedback by continuously monitoring sensor output during production and comparing it against reference values. When variations are detected, the system automatically adjusts sensor sensitivity to maintain measurement accuracy throughout the production process.
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 sensitivity calibration method and inspection device enable precise calibration of the sensitivity of the magnetic sensors, enhancing the accuracy of electromagnetic property measurements in steel sheets.
Implementation Method 1
multiple magnetic sensors are arranged on a plane parallel to the sheet surface of the steel sheet to perform measurement all along the width direction of the steel sheet, and each magnetic sensor detects leakage flux
Implementation Method 2
applying an alternating current to the wiring for calibration
Data Source
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AI summary
An inspection device 10 includes a sheet passing section 11, a magnetizer, multiple magnetic sensors, wiring for calibration, an adjustment mechanism 13, and a controller 14. The wiring for calibration is arranged at the same relative position with respect to a magnetically sensitive portion of each of the multiple magnetic sensors. The adjustment mechanism 13 can switch between retraction of the multiple magnetic sensors from a detection position and displacement of the multiple magnetic sensors to the detection position. The controller 14 obtains a first output value of each of the multiple magnetic sensors in advance. Before a predetermined portion of an electrical steel sheet passes the position of the magnetic sensors, the controller 14 retracts the multiple magnetic sensors. The controller 14 starts applying a current to the wiring for calibration. The controller 14 obtains a second output value of each of the multiple magnetic sensors. After the predetermined position passes, the controller 14 displaces the multiple magnetic sensors to the detection position. The controller 14 corrects a measurement value measured by each of the multiple magnetic sensors based on the first output value and the second output value.