System for evaluating weld quality using eddy currents

Patent metadata

Field	Value
Publication number	US-9839979-B2
Application number	US-201514978747-A
Country	US
Kind code	B2
Filing date	Dec 22, 2015
Priority date	Dec 22, 2014
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

Electromagnetic and eddy current techniques for fast automated real-time and near real-time inspection and monitoring systems for high production rate joining processes. An eddy current system, array and method for the fast examination of welds to detect anomalies such as missed seam (MS) and lack of penetration (LOP) the system, array and methods capable of detecting and sizing surface and slightly subsurface flaws at various orientations in connection with at least the first and second weld pass.

First claim

What is claimed:

1. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld, the sensor system comprising:
(a) a housing comprising a base, front and rear faces, and a support frame for retaining and supporting sensor exciter and sensor receiver elements, and comprising at least one alignment element;
(b) at least one sensor exciter element comprising a coil wound around a ferrite core;
(c) at least one sensor receiver array, the array comprising at least one sensor element comprising two orthogonally arranged receivers;
(d) at least one cooling element;
(e) an elevation system affixed to the housing at its base for supporting the housing on the surface of a welding substrate, and adapted for adjustable elevation of the housing; and
(f) a controller system engageable with the sensor exciter and receiver elements to control the actuation of the sensor and receipt and transmission of data therefrom for analysis,
(g) wherein one or more of the housing, the exciter and receiver elements, and the elevation system are rated for temperatures up to at least a preselected temperature.

2. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 , the sensor system comprising a mechanism permitting at least one element in the array of sensor receiver elements to be extended outward from the other elements in the array to be adjustably positioned in close physical proximity with the surface of a weld joint.

3. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 2 , wherein the mechanism permitting at least one element in the array of sensor receiver elements to be extended outward from the other elements in the array to be adjustably positioned in close physical proximity with the surface of a weld joint comprises a spring.

4. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 , wherein the exciter has a U-shaped ferrite core.

5. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 one or more coils wound with a good electrical-conductor wire, a coil having a ferrite core, a giant magnetic resistive sensor, and a Hall effect sensor.

6. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 , wherein the cooling element comprises within the housing one or a combination of vents, interior passages for flow of cooling fluid, and input valves for receiving fluid air flow from external cooling lines.

7. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 , wherein at least the housing is formed of material having sufficient heat resistance, good electrical conductivity, and other desirable properties suitable for use in a welding shop selected from the group including magnetic carbon steel and non-magnetic alloys such as copper and brass.

8. An eddy current sensor system for approximating real-time monitoring of weld joining processes to detect defects in a weld according to claim 1 , wherein the orthogonally arranged first and second receiver elements are oriented for positioning relative to a weld joint such that the first receiver element registers changes in an electromagnetic field normal to the weld joint, and the second receiver element registers changes in the electromagnetic field parallel to the weld joint.

9. A method for examining weld joints during or immediately following a weld process applied to the joint for detecting surface and subsurface flaws in one or more of a first, second, and any subsequent weld pass, where only the top or cap surface of each pass would be accessible for testing, the method comprising:
(a) mounting an eddy current sensor system in-line with at least one weld component selected from a laser-beam welding component, a gas-metal-arc welding, and a hybrid laser gas metal arc welding component, welding component and positioned at a distance that ranges from immediately proximate to the welding component to a distance from the welding component sufficient to limit restrict exposure of the eddy current sensor from local thermal conditions exceeding a preselected temperature, the eddy current sensor system comprising;
(i) a housing comprising a base, front and rear faces, and a support frame for retaining and supporting sensor exciter and sensor receiver elements, and comprising at least one alignment element;
(ii) at least one sensor exciter element comprising a coil wound around a ferrite core;
(iii) at least one sensor receiver comprising at least two orthogonally arranged receiver elements, each element comprising a receiver;
(iv) at least one cooling element;
(v) an elevation system affixed to the housing at its base for supporting the housing on the surface of a welding substrate, and adapted for adjustable elevation of the housing;
(vi) a controller system engageable with the sensor exciter and receiver elements to control the actuation of the sensor and receipt and transmission of data therefrom for analysis;

(b) activating the sensor and the welding component and operating the system in at least one of a first and a second mode,
(i) wherein the first mode of operation comprises deploying from the eddy current sensor a single receiving element consisting of two orthogonal X and Z receiver coils to inspect at least one weld pass of a weld joint having narrow beads/grooves, wherein the element is adapted for positioning in close proximity to the weld joint, the position ranging from direct contact with the weld joint up to 10 mm above the weld joint; and
(ii) wherein the second mode of operation comprises deploying an array of two or more receiver elements consisting of two orthogonal X and Z receiver coils to inspect at least one weld pass of a weld joint having relatively wide open beads, wherein each of the two or more elements is adapted for positioning in close proximity to the weld joint, the position ranging from direct contact with the weld joint up to 10 mm above the weld joint; and

(c) analyzing data from each of the at least first and second operational modes to identify any weld defects.

10. The method for examining weld joints according to claim 9 , wherein the eddy current sensor system comprises a mechanism permitting at least one element in the array of sensor receiver elements to be extended outward from the other elements in the array to be adjustably positioned in close physical proximity with the surface of a weld joint.

11. The method for examining weld joints according to claim 10 , wherein the mechanism permitting at least one element in the array of sensor receiver elements to be extended outward from the other elements in the array to be adjustably positioned in close physical proximity with the surface of a weld joint comprises a spring.

12. The method for examining weld joints according to claim 9 , wherein the cooling element of the eddy current sensor system comprises within the housing one or a combination of vents, interior passages for flow of cooling fluid, and input valves for receiving fluid air flow from external cooling lines.

13. The method for examining weld joints according to claim 9 , wherein the housing of the eddy current sensor system is formed of aluminum, magnetic carbon steel, and

Assignees

• Edison Welding Inst Inc

Inventors

• Todorov Evgueni I
• Hay Jacob

Classifications

• B23K2103/20

  Ferrous alloys and aluminium or alloys thereof · CPC title

• B23K2103/10

  Aluminium or alloys thereof · CPC title

• B23K2103/05

  Stainless steel · CPC title

• B23K26/21

  by welding · CPC title

• B23K31/125 Primary

  Weld quality monitoring · CPC title