Tri-Axial Sensor Array for Rapid Crack Detection
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Solution Overview
Problem
Conventional methods for detecting defects using magnetic fields are limited by slow 2D scanning, high precision requirements, and limited spatial resolution, especially when using tri-axial sensors that require numerous wires.
Innovation Solution
An apparatus with a power supply unit, sensor module, and signal reception unit, featuring first and second sensor arrays with switching elements to detect magnetic field vectors vertically and laterally, allowing for high spatial resolution 2D and 3D magnetic field distribution measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single magnetic sensor performs a 2D scan, then the measurement covers the entire area, but the measurement time becomes excessively long
Solution Approach 1:
The patent divides the measurement system into multiple magnetic sensors arranged in a matrix array, where each sensor independently measures the magnetic field at its position. This segmentation allows simultaneous multi-point measurement, dramatically reducing the time required to cover the entire measurement area compared to sequential single-sensor scanning.
Solution Approach 2:
The patent transitions from a single-sensor sequential approach to a multi-sensor parallel array configuration, adding spatial dimensionality to the measurement system. By arranging sensors in a two-dimensional matrix, the system achieves comprehensive area coverage through simultaneous measurements rather than sequential scanning.
2Productivity
If sensors are arranged in two dimensions to measure magnetic field distribution at one time, then the measurement speed improves, but the ability to quantitatively evaluate defect size is limited due to single-axis magnetic sensitivity
Solution Approach 1:
The patent employs tri-axial magnetic sensors that can detect magnetic field components in three orthogonal directions (x, y, z axes). This multi-functionality allows the sensor array to simultaneously measure both the distribution and magnitude of magnetic field vectors, enabling quantitative evaluation of defect size while maintaining high measurement speed through parallel operation.
Solution Approach 2:
The patent utilizes the vector nature of magnetic fields by measuring all three components (Bx, By, Bz) at each sensor position. This parameter expansion from single-axis to tri-axial measurement provides sufficient information to quantitatively evaluate defect characteristics including size, shape, and orientation, overcoming the limitations of single-axis sensors.
3Measurement precision
If tri-axial magnetic sensors are used to measure magnetic field distributions, then the measurement capability improves, but the spatial resolution is limited due to the large number of wires required
Solution Approach 1:
The patent integrates multiple tri-axial magnetic sensors onto a single substrate or array platform, combining their functions while sharing common wiring infrastructure. This merging approach reduces the total number of wires required compared to using individual tri-axial sensors separately, thereby improving spatial resolution without proportionally increasing wiring complexity.
Solution Approach 2:
The patent uses an array of identical tri-axial sensor units replicated across the measurement area. Each sensor unit follows the same design pattern, allowing for standardized wiring schemes and reducing overall system complexity through repetition and modularity, thus achieving high spatial resolution with manageable wire counts.
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 rapid and accurate detection of cracks by measuring magnetic field distributions in both directions, improving spatial resolution and reducing the number of wires needed, thus overcoming the limitations of existing methods.
Implementation Method 1
a sensor module to receive the power from the power supply unit and output detected signals corresponding to a magnetic field of an object to be measured
Data Source
AI summary
Disclosed herein are an apparatus and a method for detecting a crack. The apparatus includes a power supply unit, a sensor module, and a signal reception module. The power supply unit supplies power. The sensor module receives the input power from the power supply unit, and outputs sensing power corresponding to the magnetic field of an object to be measured. The signal reception unit converts the sensing power output from the sensor module into a quantitative value, and computes the distribution of the magnetic field. The sensor module includes a first sensor array configured to detect magnetic field vectors in a direction vertical to a sensor surface, and a second sensor array placed on the first sensor array in an overlapping manner and configured to detect magnetic field vectors in a direction lateral with respect to the sensor surface.