Welded Steel Pipe Magnetic Residue Detection During Longitudinal Transport
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Solution Overview
Problem
Existing methods for detecting metal residues, such as bead scraps, in electric-resistance-welded steel pipes are not sensitive enough, particularly when the pipes are transported longitudinally, as they require alignment with the pipe axis and are ineffective for pipes of varying lengths.
Innovation Solution
A method involving the use of a detecting coil to measure changes in magnetic flux induced by direct-current magnetization, allowing for the sensitive detection of metal residues by differentiating between the pipe and the residue based on cross-sectional area changes, without the need for eddy-current flaw detection techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical detection method is used to capture the inside of welded pipe, then bead scrap can be detected, but the camera must be disposed along the pipe axis which makes it inappropriate for detection while the welded pipe is transported in the longitudinal direction
Solution Approach 1:
The patent replaces the optical detection system (camera) with an electromagnetic detection system (detecting coil). The detecting coil measures changes in magnetic flux caused by metal residues, eliminating the need for visual alignment along the pipe axis and enabling detection during longitudinal transport.
Solution Approach 2:
The patent introduces magnetic flux as an intermediary between the detecting coil and the metal residue. The exciting coil generates magnetic flux that penetrates the pipe wall and interacts with metal residues, allowing indirect detection without direct visual contact or alignment requirements.
2Measurement precision
If microwave detection method is used, then bead scrap can be detected by frequency modulation or propagation damping, but the transmitter or receiver must be disposed along the pipe axis which makes it inappropriate for detection while the welded pipe is transported in the longitudinal direction
Solution Approach 1:
The patent replaces the microwave detection system with an electromagnetic coil-based detection system. The detecting coil directly measures magnetic flux changes without requiring microwave transmitters or receivers aligned with the pipe axis, enabling detection during longitudinal transport.
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
This approach enables highly sensitive detection of metal residues, even when the pipe is transported longitudinally, without requiring precise alignment or knowledge of pipe length, and can distinguish between the pipe and residues with high accuracy.
Implementation Method 1
magnetizing the electric-resistance-welded steel pipe and the metal residue up to a magnetic saturation state by the exciting coil
Implementation Method 2
an exciting coil into which the electric-resistance-welded steel pipe relatively moving in a longitudinal direction is inserted and which magnetizes the electric-resistance-welded steel pipe using a direct current
Implementation Method 3
detecting an induced electromotive force generated in the detecting coil by a change in a magnetic flux caused by the direct-current magnetization by the exciting coil
Data Source
AI summary
A method for detecting a metal residue present in an electric-resistance-welded steel pipe includes a first step of inserting the electric-resistance-welded steel pipe into an exciting coil while relatively moving the electric-resistance-welded steel pipe in a longitudinal direction and magnetizing the electric-resistance-welded steel pipe using a direct current at a field intensity capable of magnetizing the electric-resistance-welded steel pipe and the metal residue up to a magnetic saturation state by the exciting coil and a second step of inserting the electric-resistance-welded steel pipe into a detecting coil while relatively moving the electric-resistance-welded steel pipe in the longitudinal direction, detecting an induced electromotive force generated in the detecting coil by a change in a magnetic flux caused by the direct-current magnetization by the exciting coil in the first step as an output signal of the detecting coil, and detecting the metal residue present in the electric-resistance-welded steel pipe on the basis of the output signal of the detecting coil.