Model of Magnetically Shielded Ferrite-Cored Eddy Current Sensor

Computationally fast electromagnetic models of eddy current sensors are required in model-based measurements, machine interpretation approaches or in the sensor design phase. If a sensor geometry allows it, the analytical approach to the modeling has significant advantages in comparison to numerical methods, most notably less demanding implementation and faster computation. In this paper, we studied an eddy current sensor consisting of a transmitter coil with a finitely long I ferrite core, which was screened with a finitely thick magnetic shield. The sensor was placed above a conductive and magnetic half-layer. We used vector magnetic potential formulation of the problem with a truncated region eigenfunction expansion, and obtained expressions for the transmitter coil impedance and magnetic potential in all subdomains. The modeling results are in excellent agreement with the results using the finite element method. The model was also compared with the impedance measurement in the frequency range from 5 kHz to 100 kHz and the agreement is within 3% for the resistance change due to the presence of the half-layer and 1% for the inductance change. The presented model can be used for measurement of properties of metallic objects, sensor lift-off or nonconductive coating thickness.

Design and Experimental Study of Array Eddy Current Sensor for Internal Inspection of Natural Gas Pipeline

Array eddy current detection (ECAT) technology has the advantages of fast scanning speed and high detection efficiency, and has a wide range of application prospects. However, the traditional array eddy current sensor has a poor coupling effect with the inner wall of the pipeline and is not suitable for in-pipe inspection. Based on the basic principles of ECAT, a flexible array eddy current sensor made by flexible printed circuit board (FPCB) technology is designed and developed, which can realize 360° detection of defects on the inner wall of natural gas pipelines. The paper uses ANSYS finite element software to establish a simulation model of multi-parameter effects, study the influence of sensor size parameters and detection parameters on eddy current signals, carry out detection experiments on blind hole defects in the inner wall of steel pipes, analyze the response characteristics of defect signals, and verify the feasibility of using the FPCB array eddy current sensor for internal inspection of natural gas pipeline.

Classification of steel balls by resonant eddy current sensor

The quality and work-life of ball bearings depending on the material properties of the steel ball, hence it is necessary to carefully classify their properties for bearings and related applications. Classification of steel balls based on the subtle difference in their electromagnetic properties is presented in this paper. The conductivity and magnetic susceptibility for the steel balls of the same kind are measured to investigate the correlation with eddy-current signals. The developed eddy-current sensor works at the resonant frequency of 117 kHz with an optimal readout resistance of 15 kΩ, which helps to boost the signal level without a high-gain preamplifier. To detect the eddy-current signal, the steel ball under test moves through the pickup coil, and the recorded data are used to build the voltage probability map for the classification of the steel ball properties. Experimental results show that the steel balls with and without the hardening process can be identified by the change in the amplitude and phase of the eddy current signal, which is consistent with the observed change in the electromagnetic properties of steel balls. The built system can be applied to the related industries to check the quality of steel balls before use.

CALCULATION OF THE PARAMETERS OF THE WIND TURBINE ROTOR EDDY CURRENT SENSOR

Eddy current sensors are used to measure shaft clearance in wind turbines and to check that there is a thin film of oil in the clearance. In this case, the oil is usually applied under pressure. Because the eddy current sensors are resistant to oil, pressure and temperature, this allows them to operate reliably in these hostile environments. When the gap becomes too large, a maintenance warning is generated. Eddy current sensors help detect axial and radial deflection of the turbine shaft. Radial movement occurs when the shaft is off-center. Axial movement indicates that the shaft is tilted relative to the central axis. Both cannot be eliminated completely. However, with significant deviations, increased bearing wear occurs. If such situations are detected, the turbine should be shut down as soon as possible for maintenance, even before an accident occurs. Finally, eddy current sensors are used to measure forces or torques applied to the nacelle. These influences can be caused by vibration, wind loads or other factors that, over time, can lead to the destruction of the entire structure. Eddy current sensors can also be used to measure axial, radial or tangential deflection of clutch discs, which ensure the safety of the rotor in the event of strong winds. This article provides a method for calculating an inductive sensor. This calculation will allow you to correctly develop a wind turbine eddy current sensor.

Analysis of Tilt Effect on Notch Depth Profiling Using Thin-Skin Regime of Driver-Pickup Eddy-Current Sensor

Electromagnetic eddy current sensors are commonly used to identify and quantify the surface notches of metals. However, the unintentional tilt of eddy current sensors affects results of size profiling, particularly for the depth profiling. In this paper, based on the eddy current thin-skin regime, a revised algorithm has been proposed for the analytical voltage or impedance of a tilted driver–pickup eddy current sensor scanning across a long ideal notch. Considering the resolution of the measurement, the bespoke driver–pickup, also termed as transmitter–receiver (T-R) sensor is designed with a small mean radius of 1 mm. In addition, the T-R sensor is connected to the electromagnetic instrument and controlled by a scanning stage with high spatial travel resolution, with a limit of 0.2 μm and selected as 0.25 mm. Experiments were conducted for imaging of an aluminium sheet with seven machined long notches of different depths using T-R sensor under different tilt angles. By fitting the measured voltage (both real and imaginary part) with proposed analytical algorithms, the depth profiling of notches is less affected by the tilt angle of sensors. From the results, the depth of notches can be retrieved within a deviation of 10% for tilt angles up to 60 degrees.

Analysis of Tilt Effect on Notch Depth Profiling Using Thin-Skin Regime of Driver-Pickup Eddy-Current Sensor

Electromagnetic eddy current sensors are commonly used to identify and quantify the surface notches of metals. However, the unintentional tilt of eddy current sensors affects results of size profiling, particularly for the depth profiling. In this paper, based on the eddy current thin-skin regime, a revised algorithm has been proposed for the analytical voltage or impedance of a tilted driver–pickup eddy current sensor scanning across a long ideal notch. Considering the resolution of the measurement, the bespoke driver–pickup, also termed as transmitter-receiver (T-R) sensor is designed with a small mean radius of 1 mm. Besides, the T-R sensor is connected to the electromagnetic instrument and controlled by a scanning stage with high spatial travel resolution , with a limit of 0.2 μm and selected as 0.25 mm. Experiments have been out on the voltage imaging of an aluminium sheet with 7 machined long notches of different depths using T-R sensor under different tilt angles. By fitting the measured voltage (both real and imaginary part) with proposed analytical algorithms, the depth profiling of notches is less affected by the tilt angle of sensors. From the results, the depth of notches can be retrieved within a deviation of 10 % for tilt angles up to 60 degrees.