On-line eddy current testing system for spring steel wire ECH7002

Project Overview

Customers produce spring steel wire. On-line eddy current automatic flaw detection system is installed on the drawing machine.

Detecting Workpiece Information

Detection Objects Name                               Spring steel wire

Material                                                       Metal materials such as ferromagnetic materials

Dimension Specification                               Φ2-40mm (Two sets of probe/guide sleeve are customized within this range)

Weld Width                                                 /

Length                                                         Disk material

Bending Degree                                           1.5mm/m ( Of the detection station)

Roughness                                                   Round surface (chamfered end without convex burr)≦3.2, no oxide scale.

Hardness                                                     Harder

Detection Speed                                          Recommended through speed≦100m/min Adjustable 

                                                                   (Instrument detection speed: 0.52-750m/min)

Detection Part Temperature                          ≦80°C

Detection Requirement and Accuracy Standard

                                                               Executive Standard of Detection

Number of Standard                                         Name of Standard                                                               Grade

GB/T 11260-2008             Eddy Current Detection Method for Round Steel (Through Type)                           Grade 2

GB/T 14480-2015            Nondestructive Testing Instrument     Eddy Current Testing Equipment                        /

Technical Parameter of the System

Name of the System: On-line eddy current testing system for spring steel wire

Type: ECH7002

Detection Method: Dual-channel through type detection

Control Mode: Automatic + Manual

Instrument and Probe: Eddy current instrument; Dual Channel Digital High Intelligence Eddy Current Flaw Detector and Probe

Detection Platform: Core detection platform independently developed

Brief Introduction of Detection Operation:

Adjust the technical parameters and standard samples of flaw detector according to the testing requirements;

Adjust the position of probe and probe according to workpiece specifications;

The flaw detection system detects the workpiece, alarms and marks;

Spring steel wire can be repaired by shutdown during the process;

Data recording, storage and analysis are carried out by the flaw detection host;

Automatically form flaw detection report.

Important Parameters of the System

Name                                                 Technical Parameter                                               Remarks

End Blind Area                                           ≦500m                                               Depending on the test speed

Stability                                              After 16 hours≦2dB                                              Test sample

Accuracy of Jet Printing                              ±50mm                                                        Test sample

Omissive Judgement Rate                              0%                                                             Test sample

Misreporting Rate                                         ≦2%                                                           Test sample

Test Speed                                     Recommended through speed≦100m/min                     Test sample

                                       Adjustable (Instrument detection speed: 0.52-750m/min)

Principle of Through Type Eddy Current Testing

Eddy current detection is to establish alternating magnetic field by approaching conductor to the coil with alternating current (referred to as the probe). The alternating magnetic field passes through the conductor and produces electromagnetic induction with it, and establishes eddy current in the conductor. The eddy current in the conductor will also produce its own magnetic field. The effect of the eddy current magnetic field will also change the strength of the original magnetic field, which will lead to the change of coil voltage and impedance. Therefore, when defects occur on or near the surface of conductor or or the measured metal material changes, the strength and distribution of eddy current will be affected, and the change of eddy current will cause the change of voltage and impedance of detection coil. According to this change, the existence of defects in conductor and the performance of metal material can be known.

General Description of the System

The online system includes intelligent digital dual-channel flaw detector, customized detection platform (including magnetic saturation and demagnetization devices), through-type detection device, probe, alarm system, marking system, customized genuine detection software and automation module.

Workflow of the System

This project adjusts the technical parameters of flaw detector according to testing requirements, testing standard sample→workpiece enters uniformly through front and rear clamping mechanism→detection probe detecting automatically→detection finished→ automatic alarm and mark the detect when the system detects workpiece defect→output signal of shutdown and grinding to production organization during testing process→data recording, storage and analysis are carried out by the flaw detection host and other works. 100% coverage detection can be achieved. And it can automatically generate the detection report for the on-duty detecting situation: detection batch, quantity, good product/waste rate, etc.