Virtual Eddy Current Thinning Detection for Metal Equipment
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Solution Overview
Problem
Existing thinning detection technologies face challenges in accurately estimating the shape and depth of corrosion-induced thinning in metal equipment, particularly when the thinning patterns are varied, as they rely on pattern matching which has limited accuracy for unmatched patterns and require extensive preparation of magnetic field distribution data.
Innovation Solution
A system comprising a current applying apparatus, a magnetic-field measuring apparatus, and a measurement managing apparatus that calculates a virtual current distribution from magnetic field differences to estimate thinning distribution using a virtual eddy current, allowing for estimation of shape and depth based on spiral direction and density, and approximates current paths using an oriented square lattice to minimize magnetic field distribution differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If pattern matching technology is used to estimate thinning shape and depth from magnetic field distribution changes, then estimation accuracy is improved for patterns that match pre-prepared data, but the system cannot accurately estimate thinning that does not match any pre-prepared patterns
Solution Approach 1:
The patent creates a virtual copy of the current distribution by calculating the difference between measured and reference magnetic field distributions. This virtual current distribution serves as a model that represents the actual thinning pattern without requiring physical pattern matching, enabling accurate estimation of any thinning shape.
Solution Approach 2:
The patent transforms the problem from pattern matching to parameter extraction by changing the approach: instead of matching entire patterns, it extracts thinning shape and depth parameters directly from the virtual current distribution characteristics, allowing accurate estimation for any thinning pattern.
2Measurement precision
If pattern matching scheme prepares multiple thinning patterns in advance, then estimation accuracy is improved for matching cases, but the complexity and data preparation requirements increase significantly
Solution Approach 1:
Instead of preparing multiple reference patterns, the system creates a virtual copy of the current distribution specific to each measurement by calculating magnetic field differences. This eliminates the need for extensive pre-prepared pattern databases while maintaining high estimation accuracy.
Solution Approach 2:
The system performs self-calibration by using the measured magnetic field distribution itself to generate the virtual current distribution. The measurement data serves its own reference function, eliminating the need for external pre-prepared patterns and reducing data preparation complexity.
3Ease of operation
If magnetic field distribution measurement is performed to detect thinning, then non-contact inspection is achieved, but the ability to immediately obtain thinning shape and depth information is lost
Solution Approach 1:
The patent introduces a virtual current distribution as an intermediary between the magnetic field measurement and the thinning characteristics. This virtual distribution serves as a mediator that translates magnetic field changes into meaningful thinning shape and depth information without requiring contact with the inspection object.
Solution Approach 2:
The system transforms the magnetic field distribution data into virtual current distribution parameters, and further extracts thinning shape and depth parameters from these virtual current characteristics. This parameter transformation chain enables immediate获得 of thinning information while maintaining non-contact measurement.
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 accurate detection and estimation of thinning distribution across various shapes without the need for pre-prepared patterns, improving estimation accuracy and adaptability to diverse thinning shapes in metal equipment.
Implementation Method 1
a current applying apparatus configured to apply an AC current to electrodes installed on metal equipment which is a monitoring object
Implementation Method 2
a magnetic-field measuring apparatus including an array of magnetic sensors configured to measure a magnetic field distribution of a surface side of the metal equipment
Implementation Method 3
the measurement managing apparatus calculates a virtual current distribution of the metal equipment from the magnetic field distribution difference, and estimates the thinning distribution of the metal equipment on the basis of a virtual eddy current represented by the virtual current distribution
Data Source
AI summary
A thinning detection system includes a current applying apparatus configured to apply an AC current to electrodes installed on metal equipment which is a monitoring object, a magnetic-field measuring apparatus including an array of magnetic sensors configured to measure a magnetic field distribution of a surface side of the metal equipment; and a measurement managing apparatus configured to estimate a thinning distribution of the metal equipment based on a magnetic field distribution difference which is a difference between a reference magnetic-field distribution which is obtained in a case where thinning has not occurred in the metal equipment and a measurement magnetic-field distribution which is an actual measurement result. The measurement managing apparatus calculates a virtual current distribution of the metal equipment from the magnetic field distribution difference, and estimates the thinning distribution of the metal equipment on the basis of a virtual eddy current represented by the virtual current distribution.