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배열 와전류 기술을 이용한 자동 표면 검사


Introduction

Inspecting the surface of long bars and tubes has been a requirement in the metal manufacturing industry for many years. Material quality and performance requirements are continuously evolving with respect to the various types, orientations, and sizes of surface indications. While different technologies can be used to detect surface defects, eddy current array (ECA) stands out due to its ability to adapt to various geometries and deviations on both ferromagnetic and nonferromagnetic products.

Challenges

The tube and bar manufacturing process can disrupt the optimal product parameters by causing variations in the geometry (ovality, hooks, and bending) and surface conditions (pits, scale, and burrs). The part’s condition has a significant impact on the quality of the inspection. Therefore, the probe’s ability to maintain an optimal position during inspection while adapting to the part’s condition is critical.

Example of the rough surface condition found on many production bars

Solution

Olympus’ ECA probe technology uses printed circuit boards (PCBs), enabling an increase in the lift-off distance while improving the inspection performance. This improvement enabled us to integrate a hard-ceramic face to the probe assembly to shield it from the tube or bar’s rough surface.

The probe’s technology and design enable the detection of longitudinal- and transverse-orientated flaws. Specific probe designs can detect flaws in any 360-degree orientation.

ECA probe with a ceramic face

ECA probe with a ceramic face for in-line tube or bar inspection

Olympus ECA smart probes have embedded monitoring and live integrity validation features. They are accessible via the acquisition unit software interface and enable users to get detailed health information and live status updates about the most critical components of the inspection systems. In a turnkey solution, these features can be used to evaluate the probe’s scan-to-scan detection integrity to set or raise alarms that warn of out-of-tolerance conditions during an inspection or to facilitate diagnostics.

Results

Depending on the application, the probe, wedge, and shoe are specifically designed to fit the part being inspected to improve the assembly’s durability.

To test the design, we mounted a probe to a complete mechanical assembly that mimicked the normal operating conditions for in-line tube and bar inspection.

Example of a mechanical assembly

Example of a mechanical assembly

Over 3000 km (1864 miles) of long metal parts were inspected at various speeds of up to 2 meters/second. Only minor damage, mostly scratches, could be seen on the probe’s ceramic face. No performance variation or degradation were measured when comparing inspection results from before and after the test.

Ceramic face of an ECA probe showing minor abrasions post testing

Ceramic face of an ECA probe showing minor abrasions post testing

Conclusion

This next-generation ECA probe’s rugged design offers durability and versatility for manufacturing inspection applications.

The use of eddy current array brings many advantages to surface inspection, including:

  • The ability to inspect ferromagnetic and nonferromagnetic products (no product magnetization required)
  • Longitudinal- and transverse-oriented flaws with extended capabilities up to 360 degrees
  • Enhanced detection and speed capabilities
  • Extremely durable with a long useful life
Olympus IMS

이 애플리케이션에 사용되는 제품
이 BIS는 배열 와전류(ECA) 기술을 사용하여 원형 및 사각 막대의 전체 표면을 검사합니다. 이 시스템은 막대의 직선도의 변화에 무관하게 ECA 프로브의 위치를 지속적으로 최적화하는 마모 슈를 사용합니다.
RBIS는 위상 배열 및 배열 와전류 기술을 결합하여 철강괴라고 부르는 대형 원형 막대의 전체 체적 및 표면을 검사합니다. 검사는 철강괴가 회전하는 도중과 검사 헤드를 지지하는 캐리지가 선형 운동하는 도중에 수행됩니다.
RTIS는 위상 배열 기술을 사용하여 튜브 전체를 검사합니다. 이 시스템은 신속한 결합과 짧은 비검사 거리를 제공하는 영구적이고 안정적인 물 챔버를 유지하기 위해 막을 사용하는 '물 쐐기(Water Wedge)' 개념에 기초합니다.
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