621.3 Elektrotechnik, Elektronik
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- Fachbereich 4 - Institut Mess- und Senstortechnik (54) (remove)
Methods of red-hot rod shape testing require a robust non-contact measurement principle as a touch point could lead to damages to the rod and the detection unit. Therefore a new basic approach based on high frequency eddy current (HFEC) has been investigated. Due to the robustness and the ability to determine the rod shape even above the Curie temperature this principle is especially well suited and can be implemented in the production process directly. The first automatic measurement setup was successfully developed with promising results. Hereby a defect of ovality was detected with a parallel RLC-oscillator. The capacity of this RLC-oscillator is constant whereas the inductance is the measurement part that varies due to eddy current interactions with the rod.
Optimization of Encircling Eddy Current Sensors for Online Monitoring of Hot Rolled Round Steel Bars
(2014)
Modern manufacturing industries are continually working on quality enhancements for the hot rolling process of round products. One method for improving the finalisation of the rods is the implementation of an automatic size control system. As a result of these trends over the last few years, there has been an increasing demand for more accurate online measurements. Thus the reason for the research performed for this thesis. A particular challenge throughout this research was dealing with the temperature changes (up to 1200°C) from the in- and output of the fervent rolling stocks, and the effect this temperature changes had on the sensors. Furthermore, there is also high demand for developing fast and practical electronic measuring equipment, capable of measuring during high transport velocities (up to 120 m/s). The eddy current principle is just one of the very few methods available which can with-stand such harsh industrial environments. In fact, eddy current sensors are already being integrated into online monitoring tasks for hot rolling processes. The measurement uncertainty, however, is still considerably large for process control purposes. One reason for this lies within the ability for eddy current detectors to receive signals influenced by outward forces, i.e. forces dependent on its location, its geometry, the outside temperature and the material properties of a particular target. Thus the current accuracy for a cross-sectional area measurement, for example, is no higher than 1%. As a result, this thesis investigates the magnitude of all individual influential factors on the eddy current detectors, using model-based analysis techniques. The analytical model provides a solution for all rotationally symmetrical targets and the FEA model covers all of the other influencing parameters in a more time consuming manner. This thesis then provides different methods which are developed to separate the cross-sectional area measurement of a rod from all of the other influencing parameters. In addition, a material tracking approach for round products is developed. Two different kinds of prototypes, capable of measuring approximately 466 Tons of red-hot steel rods during the production process, are finally introduced in this thesis. The usefulness of the eddy current principle is validated by the provided field test results. The count accuracy for the identification of 2876 bars was found to be 99.93%, and the average measurement accuracy for the cross-sectional area experiments was reduced to ± 0.29 % when including all of the findings.
Electro-magnetic acoustic transducers (EMATs) are intended as non-contact and non-destructive ultrasound transducers for metallic material. The transmitted intensities from EMATS are modest, particularly at notable lift off distances. Some time ago a concept for a “coil only EMAT” was presented, without static magnetic field. In this contribution, such compact “coil only EMATs” with effective areas of 1–5 cm2 were driven to excessive power levels at MHz frequencies, using pulsed power technologies. RF induction currents of 10 kA and tens of Megawatts are applied. With increasing power the electroacoustic conversion efficiency also increases. The total effect is of second order or quadratic, therefore non-linear and progressive, and yields strong ultrasound signals up to kW/cm2 at MHz frequencies in the metal. Even at considerable lift off distances (cm) the ultrasound can be readily detected. Test materials are aluminum, ferromagnetic steel and stainless steel (non-ferromagnetic). Thereby, most metal types are represented. The technique is compared experimentally with other non-contact methods: laser pulse induced ultrasound and spark induced ultrasound, both damaging to the test object’s surface. At small lift off distances, the intensity from this EMAT concept clearly outperforms the laser pulses or heavy spark impacts.
A simple copper coil without a voluminous stationary magnet can be utilized as a non-contacting transmitter and as a detector for ultrasonic vibrations in metals. Advantages of such compact EMATs without (electro-)magnet might be: applications in critical environments (hot, narrow, presence of iron filings…), potentially superior fields (then improved ultrasound transmission and more sensitive ultrasound detection).
The induction field of an EMAT strongly influences ultrasound transduction in the nearby metal. Herein, a simplified analytical method for field description at high liftoff is presented. Within certain limitations this method reasonably describes magnetic fields (and resulting eddy currents, inductances, Lorentz forces, acoustic pressures) of even complex coil arrangements. The methods can be adapted to conventional EMATS with a separate stationary magnet.
Increased distances (liftoff) are challenging and technically relevant, and this practical question is addressed: with limited electrical power and given free space between transducer and target metal, what would be the most efficient geometry of a circular coil? Furthermore, more complex coil geometries (“butterfly coil”) with a concentrated field and relatively higher reach are briefly investigated.
This experimental study demonstrates for the first time a solid-state circuitry and design for a simple compact copper coil (without an additional bulky permanent magnet or bulky electromagnet) as a contactless electromagnetic acoustic transducer (EMAT) for pulse echo operation at MHz frequencies. A pulsed ultrasound emission into a metallic test object is electromagnetically excited by
an intense MHz burst at up to 500 A through the 0.15 mm filaments of the transducer. Immediately thereafter, a smoother and quasi “DC-like” current of 100 A is applied for about 1 ms and allows an
echo detection. The ultrasonic pulse echo operation for a simple, compact, non-contacting copper coil is new. Application scenarios for compact transducer techniques include very narrow and
hostile environments, in which, e.g., quickly moving metal parts must be tested with only one, non-contacting ultrasound shot. The small transducer coil can be operated remotely with a cable
connection, separate from the much bulkier supply circuitry. Several options for more technical and fundamental progress are discussed.
The detection of soil erosion processes in dams, hydraulic heave failure or corrosion processes of reinforcing steel in concrete are a small selection of measuring applications in civil engineering where the impedance analysis can be used to determine the measurand. Those measuring applications are having high requirements for the measuring hardware. For example a common interface for fast data exchange, high resolution, independent functionality and easy customizability to suit the measuring application. For that reason, a well-known application for steel-mill process monitoring can be used as a development platform. This hardware platform is based on a vector network analyzer and is meeting the requirements mainly. However, a couple of modifications has to be made, like replacing the ADC for a higher sample rate, Ethernet for easy and fast data exchange and the microcontroller for more calculation power.
Process diagnosis is an important method for improving product quality in rolling mills. In addition, the measurement of process variables such as roll gap, cross-sectional area, velocity, and volume flow of the material during production enables the implementation of model-based control concepts to improve product quality. The non-contact speed measurement of hot wire and bar is still a big challenge due to the rough environmental conditions and is solved mainly with optical measuring methods in production. The alternative measurement principle with eddy current sensors presented in this paper enables velocity measurement at locations in a rolling mill where optical measurement methods are not suitable.