Magnetic Sensor Module for Surface Unevenness Detection
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Solution Overview
Problem
Existing surface inspection technologies are limited in detecting unevenness, particularly in vertical operations, and struggle with adaptability to various applications due to restrictive orientations and difficulty in adjusting optics, as well as limited size detection ranges.
Innovation Solution
A sensor module comprising an arm assembly with surface contacting elements, a magnet assembly for generating magnetic lines of force, and a magnetic sensor assembly to detect changes in these lines, allowing for multi-directional operation and effective detection of surface unevenness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical detection methods are used for surface inspection, then detection precision can be improved, but the device complexity and difficulty of adjusting optics increase
Solution Approach 1:
The patent replaces complex optical detection systems with a magnetic field-based sensor module. Instead of using optics that require precise alignment and adjustment, the invention uses a magnet assembly and magnetic sensor assembly that detect surface unevenness through magnetic field changes, significantly simplifying the device structure while maintaining detection capability
Solution Approach 2:
The invention changes the detection parameter from optical properties to magnetic field properties. By measuring changes in magnetic field strength or distribution caused by surface deformations, the system achieves detection functionality without requiring complex optical alignment and adjustment mechanisms
2Measurement precision
If large angle of incidence is used for light irradiation, then detection capability is improved, but it becomes difficult to introduce apparatus into actual operation line
Solution Approach 1:
The patent replaces the optical irradiation system requiring large angles of incidence with a magnetic field-based sensor module. The magnet assembly generates magnetic field lines that penetrate the surface at various angles, and the magnetic sensor assembly detects changes in these field lines, eliminating the need for complex angular positioning while maintaining detection capability
Solution Approach 2:
The sensor module is designed to be universally applicable in various operational contexts including horizontal, vertical, and inclined surfaces. The magnetic field-based detection mechanism works effectively regardless of the surface orientation, making the apparatus easy to introduce into different operation lines without requiring angle-specific configurations
3Measurement precision
If existing detection methods are used, then detection of specific defect sizes is achieved, but adaptability to various applications is limited
Solution Approach 1:
The sensor module is designed with universal adaptability to detect surface unevenness across various applications and orientations. The magnet assembly and magnetic sensor assembly configuration allows the system to detect defects on horizontal surfaces, vertical surfaces, and inclined surfaces, making it adaptable to different industrial applications without requiring reconfiguration
Solution Approach 2:
The sensor module incorporates dynamic positioning capabilities with the arm assembly that can adjust the position and orientation of the magnet and magnetic sensor assemblies. This dynamic adjustment allows the system to adapt to different detection scenarios and surface geometries, enhancing versatility across various applications
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 efficient detection of surface unevenness in narrow spaces and various orientations, including horizontal, incline, and vertical directions, providing accurate profiles of surface deformation.
Implementation Method 1
a magnet assembly (2) comprising at least one magnet (2.1) to generate magnetic lines of force
Implementation Method 2
a magnetic sensor assembly (3) comprising a magnetic sensor (3.1) being assembled adjacent to the magnet (2.1) for sensing changes in the magnetic lines of force
Data Source
AI summary
The present invention relates to a sensor module for detecting unevenness of a surface, especially for detecting bulging and bowing of the pipe external surface. The sensor module comprises an arm assembly comprising an arm body having at least two ends, one or more surface contacting element mounted to at least one end of the arm body; a magnet assembly comprising at least one magnet to generate magnetic lines of force; and a magnetic sensor assembly comprising a magnetic sensor being assembled adjacent to the magnet for sensing changes in the magnetic lines of force in response to movement of the arm body. The invention also relates to an apparatus comprising the said sensor module and a method for detecting unevenness of a surface using the said sensor module.