Tubular Element Thickness Detection via Electromagnetic Induction

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Solution Overview

Problem

Existing methods for detecting deformity in thickness of tubular elements during production are complex, sensitive to positioning, and prone to errors due to the independence of rolling rings and eccentricity issues, leading to suboptimal quality and performance of the final product.

Innovation Solution

A detection apparatus using a plurality of sensors disposed circumferentially around the tubular element, generating a variable magnetic field to detect thickness without contact, allowing for accurate measurement of each portion of the tubular element's thickness, reducing the need for auxiliary equipment and simplifying the detection process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If X-ray radiation principle is used to detect thickness, then measurement capability is provided, but device complexity increases and positioning sensitivity causes errors

Engineering Contradiction:

Improvethickness measurement capabilityVSAvoiddetection system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex X-ray radiation detection systems with a simpler electromagnetic induction-based sensor system. The sensor uses a magnetic field generator and detector to measure thickness through electromagnetic induction, eliminating the need for radioactive sources and complex shielding while maintaining measurement capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the sensor and the tubular element for thickness measurement. The magnetic field penetrates the material and induces eddy currents, providing a non-contact measurement mechanism that is less sensitive to positioning errors compared to direct physical contact or X-ray methods.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple X-ray probes are disposed around circumference, then comprehensive detection is achieved, but measurement reliability decreases due to inability to distinguish uniformity

Engineering Contradiction:

Improvecircumferential detection coverageVSAvoidthickness uniformity verification reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent divides the circumferential detection into multiple discrete sensor positions around the tubular element. Each sensor independently measures thickness at its specific angular position, allowing the system to detect both overall thickness and local variations. This segmented approach provides reliable uniformity verification by comparing measurements from different circumferential locations.

Inventive Principle:

Principle #1Segmentation

3Shape

If rolling rings are used to reduce section measurement, then shaping capability is provided, but deformity in thickness occurs due to ring independence and eccentricity

Engineering Contradiction:

Improvetubular element profileVSAvoidthickness uniformity

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The patent implements a feedback system where thickness measurements are taken during the rolling process, and the data is used to adjust rolling ring positions or speeds in real-time. This closed-loop control compensates for thickness variations caused by ring independence and eccentricity, maintaining manufacturing precision while preserving the shaping capability of the rolling rings.

Inventive Principle:

Principle #23Feedback

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 solution provides reliable, economical, and easy-to-use thickness measurement, reducing errors and ensuring uniformity over the entire circumference, while being less sensitive to environmental conditions and positioning, thus enhancing the quality and performance of the tubular elements.

Implementation Method 1

Each of the sensors (16) comprises at least a transmission element (18), able to generate a variable magnetic field inside the thickness of the tubular element (40), and a reception element (19) through which an electric current generated by the variable magnetic field is able to pass

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The variable magnetic field generated by the transmission element of each sensor determines the circulation of parasite currents inside a corresponding portion of the thickness of the tubular element (40). The parasite currents in turn generate another variable magnetic field that hits and is detected by the corresponding reception element

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Data Source

PatentEP2864065B1Apparatus to detect the deformity in thickness of tubular elements and corresponding method

Publication Date: 2018.10.31 DANIELI AUTOMATION SPA

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AI summary

Apparatus to detect a deformity in thickness of a tubular element (40). The apparatus comprises a plurality of sensors (16) and is installed in at least a rolling stand (11), having at least three rolling rings (12), of a rolling train (50) able to obtain said tubular element (40).