Patent Description:
Generally, in eddy current detection, alternating current from an alternating current power source is supplied to an excitation coil to induce eddy current in the vicinity of a surface of a tested object made of a metal material. A reactive magnetic field generated by the eddy current is detected by a detection coil. If there is a flaw in the vicinity of the tested object, the eddy current would change due to the flaw, and intensity and distribution of the reactive magnetic field generated by the eddy current would also change. Thus, the flaw can be detected.

A complex material, which is composed of a plurality of different materials in a layer structure or with fiber structure, may have a lower electric conductivity compared to metals. When a tested object is made of a complex material in an eddy current flaw detection, eddy current density induced in the complex material becomes low due to the low electric conductivity of the complex material. Thus, the magnetic flux density in the reactive magnetic field generated by the eddy current becomes low, and flaw detection sensitivity becomes low.

<CIT> relates to the detection of a magnetic response to eddy currents induced in an object to be tested.

A technique using a magnetic flux meter of a superconducting quantum interference device (SQUID) is known to improve flaw detection sensitivity of eddy current flaw detection under a weak magnetic field. With such a technique, improvement in flaw detection sensitivity of eddy current flaw detection under a weak magnetic field is expected owing to the high sensitivity of the SQUID magnetic flux meter to a magnetic field. However, the SQUID magnetic flux meter requires a cooling mechanism, and the device has a complex structure. Thus, the device is expensive, which is a problem to be solved.

The complex material may have a lower electric conductivity compared to metals. When a tested object of the eddy current flaw detection is made of a complex material, the eddy current density in the tested object is lowered and the magnetic flux density generated by the eddy current is lowered, and then, the flow detection sensitivity in the eddy current flaw detection is deteriorated. On the other hand, if a highly sensitive magnetic detector is used as a detector for eddy current flaw detection, the device may have a complex structure and may become expensive.

An object of the embodiments of the present invention is to enable eddy current flaw detection with a simplified and inexpensive device, with high sensitivity, even with a tested object made of a low electric conductivity material such as a complex material.

In order to solve the problems, according to an embodiment, there is presented an eddy current flaw detection device comprising: a first exciter/detector configured to induce eddy current in a tested object; a second exciter/detector disposed opposite side of the first exciter/detector sandwiching the tested object therebetween, the second exciter/detector being configured to detect a change in a reactive magnetic field generated by the eddy current.

According to another embodiment, there is presented an eddy current flaw detection device comprising: an exciter/detector configured to induce eddy current in a tested object and to detect a change in a reactive magnetic field generated by the eddy current; a backside body made of ferromagnetic material disposed opposite side of the exciter/detector sandwiching the tested object therebetween,.

According to yet another embodiment, there is presented an eddy current flaw detection method comprising: a first exciter/detector disposing step of disposing a first exciter/detector near a tested object; a second exciter/detector disposing step of disposing a second exciter/detector near the tested object at an opposite side of the first exciter/detector sandwiching the tested object therebetween; an excitation step, after the first and second exciter/detector disposing steps, of inducing eddy current in the tested object by the first exciter/detector; and a detection step of detecting, by the second exciter/detector, a change of reactive magnetic field generated by the eddy current.

According to yet another embodiment, there is presented an eddy current flaw detection method comprising: an exciter/detector disposing step of disposing an exciter/detector near a tested object; a backside body disposing step of disposing a backside body made of ferromagnetic material, near the tested object at an opposite side of the exciter/detector sandwiching the tested object therebetween; an excitation step, after the exciter/detector disposing step and the backside body disposing step, of inducing eddy current in the tested object by the exciter/detector; and a detection step of detecting, by the exciter/detector, a change of reactive magnetic field generated by the eddy current.

According to the embodiments of the present invention, eddy current flaw detection can be conducted with a simplified and inexpensive device, with high sensitivity, even with a tested object made of a low electric conductivity material such as a complex material.

Hereinafter, eddy current flaw detection devices and eddy current flaw detection methods according to embodiments of the present invention will be described with reference to the drawings. In the following description, same or similar parts are assigned common references, and repetitive explanation will be omitted.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a first embodiment of the present invention.

In the first embodiment, a tested object <NUM> is made of a complex material which has a lower electric conductivity compared to ordinary metals. The complex material may include a complex material using silicon carbide fibers, carbon fiber reinforced plastics (CFRP) or glass fiber reinforced plastics (GFRP). The tested object <NUM> is shaped in a flat plate, and has a first flat surface <NUM> and a second flat surface <NUM> which is an opposite side of and parallel to the first flat surface <NUM>, for example. A flaw (a thinner part) <NUM> is assumed to exist on the first flat surface <NUM>.

The eddy current flaw detection device according to the first embodiment has an exciter <NUM> as a first exciter/detector and a detector <NUM> as a second exciter/detector. Each of the exciter <NUM> and the detector <NUM> may include a helical coil, for example. The exciter <NUM> is disposed on the first flat surface <NUM> of the tested object <NUM>, while the detector <NUM> is disposed on the second flat surface <NUM> of the tested object <NUM>. The exciter <NUM> and the detector <NUM> are disposed so that the axis A of the coils is directed perpendicular to the first flat surface <NUM> and the second flat surface <NUM>. The exciter <NUM> is connected to an alternating current power source <NUM>. The detector <NUM> is connected to a detector circuit (not illustrated).

Coil wire elements constituting the exciter <NUM> are thicker than those constituting the detector <NUM> in order to suppress Joule loss in the exciter <NUM>, because larger electric current is needed to flow in the exciter <NUM>.

When alternating current is supplied from the alternating current power source <NUM> to the exciter <NUM>, a variating magnetic field is generated around the exciter <NUM>. Examples of magnetic force lines M are shown as dash lines in <FIG>. The magnetic field generated by the exciter <NUM> is substantially symmetrical around the axis A of the exciter <NUM>, although magnetic force lines M on only right side are illustrated in <FIG>.

Since the variating magnetic field is generated around the exciter <NUM>, eddy current is induced in the tested object <NUM>. The eddy current causes a reactive magnetic field to be generated. The reactive magnetic field is detected as a voltage by the detector <NUM> and the detector circuit. Since the reactive magnetic field changes because of the flaw <NUM>, the flaw <NUM> can be detected as a change in the voltage by the detector circuit.

If the tested object <NUM> is made of an ordinary metallic material, most of the magnetic flux passes through the tested object <NUM> as a result of skin effect, and substantially no magnetic field exists on the back surface (the second flat surface <NUM>) of the tested object <NUM>. In a case where the tested object <NUM> is a stainless steel plate of <NUM> thickness and alternating current of a frequency of <NUM> is supplied, depth of penetration with the skin effect would be about <NUM>.

On the other hand, if the tested object <NUM> is made of a complex material, depth of penetration of the magnetic field due to the skin effect is larger compared to that in case of ordinary metal. Therefore, the magnetic field penetrates the tested object <NUM>, and there exists the magnetic field even on the back surface (the second flat surface <NUM>) of the tested object <NUM>. However, the magnetic flux density in the tested object <NUM> is lower than that in the tested object <NUM> of ordinary metal.

In the present embodiment, the exciter <NUM> and the detector <NUM> are separated and disposed sandwiching the tested object <NUM> therebetween. Thus, the exciter <NUM> and the detector <NUM> can be disposed close to the tested object <NUM>. Thus, the detector <NUM> can be disposed at a location where the magnetic flux density is relatively high, which results in a relatively high accuracy in the flaw detection.

The exciter <NUM> and the detector <NUM> may not have a same structure or a same specification. They can be designed to have different coil wire element thicknesses, different numbers of turns, different shapes and different sizes, for example, to fit their respective coils. The coils of the exciter <NUM> preferably have thicker coil wire elements because relatively larger electric current is needed to flow there. On the other hand, the coils of the detector <NUM> preferably have thinner coil wire elements and more wire turns, because the coils of the detector <NUM> do not need to allow large electric current while it is preferred to have a larger voltage output to be gained.

When the tested object <NUM> is made of a low electric conductivity material such as a complex material, highly sensitive flaw detection can be conducted by setting the power source with higher frequency which would result in a smaller penetration depth. Therefore, the frequency of the power source is preferably in order of MHz.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a second embodiment of the present invention.

The eddy current flaw detection device according to the second embodiment has a first exciter/detector <NUM> and a second exciter/detector <NUM>.

The first exciter/detector <NUM> and the second exciter/detector <NUM> are both helical coils, for example. The first exciter/detector <NUM> is disposed on the first flat surface <NUM> of the tested object <NUM>, while the second exciter/detector <NUM> is disposed on the second flat surface <NUM> of the tested object <NUM>. The first exciter/detector <NUM> and the second exciter/detector <NUM> are disposed so that the axis A of the coils is directed perpendicular to the first flat surface <NUM> and the second flat surface <NUM>. The first exciter/detector <NUM> is connected to an alternating current power source <NUM>. The second exciter/detector <NUM> is connected to another alternating current power source 22a. The first exciter/detector <NUM> and the second exciter/detector <NUM> are connected to respective detector circuits (not illustrated).

The first exciter/detector <NUM> and the second exciter/detector <NUM> have substantially same structures, and each has both functions of an exciter and a detector. The alternating current power sources <NUM> and 22a may have same structures, and preferably, they have the same frequency and the same phase, synchronizing each other. Alternatively, the alternating current power sources <NUM> and 22a may be a single alternating current power source.

According to the second embodiment, effects of the excitation actions in the first exciter/detector <NUM> and the second exciter/detector <NUM> are combined together, and higher density of magnetic flux is obtained. Then, eddy current induced in the tested object <NUM> would be enhanced, which would result in a larger change in reactive magnetic flux generated by the eddy current. Then, relatively large voltage change is detected by the first exciter/detector <NUM> and the second exciter/detector <NUM> which function as detectors. In addition, still larger voltage change can be detected by adding the voltages obtained by the first exciter/detector <NUM> and the second exciter/detector <NUM> which function as detectors.

In the above description, the alternating current supplied to the first exciter/detector <NUM> and the second exciter/detector <NUM> have preferably same frequency and same phase and are synchronized with each other. However, even in cases where such a condition is not satisfied, the magnetic fields generated by the first exciter/detector <NUM> and the second exciter/detector <NUM> may be enhanced by each other in some other conditions, and flaw detection may be conducted in such other conditions where the magnetic fields are enhanced by each other.

In addition, in the above description, both the first exciter/detector <NUM> and the second exciter/detector <NUM> function as detectors, and the voltage signals detected by them are added. However, the voltage signals detected by the first exciter/detector <NUM> and the second exciter/detector <NUM> may be processed for flaw detection, by subtraction rather than addition, depending on the phase relation between the alternating currents supplied to the first exciter/detector <NUM> and the second exciter/detector <NUM>.

Further alternatively, it would be possible that only one of the first exciter/detector <NUM> and the second exciter/detector <NUM> is used as a detector and the voltage signal from the one is used for flaw detection.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a third embodiment of the present invention.

The third embodiment is a modification of the second embodiment. In the third embodiment, the outer surfaces of the first exciter/detector <NUM> and the second exciter/detector <NUM> except the parts facing the tested object <NUM> are covered with covers <NUM> made of ferromagnetic material. The other structures are the same as the structures of the second embodiment.

According to the third embodiment, the effects of the second embodiment are obtained. In addition, the magnetic field generated by supplying alternating current to the first exciter/detector <NUM> and the second exciter/detector <NUM> is distributed along the magnetic path formed in the covers <NUM> of ferromagnetic material, and the magnetic flux density would be enhanced. Thus, the magnetic flux density penetrating the flaw <NUM> and crossing the first exciter/detector <NUM> or the second exciter/detector <NUM> can be enhanced, which enables highly sensitive flaw detection.

In the example shown in <FIG>, all portions of the first exciter/detector <NUM> and the second exciter/detector <NUM> which do not face the tested object <NUM> are covered with the covers <NUM> of ferromagnetic material. As a modified example, alternatively, only some portions of the first exciter/detector <NUM> and the second exciter/detector <NUM> which do not face the tested object <NUM> are covered with the covers <NUM>. Even in such a modified case, the effect of the covers <NUM> of ferromagnetic material can be partially obtained.

The third embodiment described above is a modification of the second embodiment, and the outer surfaces of the first exciter/detector <NUM> and the second exciter/detector <NUM> except the parts facing the tested object <NUM> are covered with covers <NUM> of ferromagnetic material. As a modification of the third embodiment, alternatively, the outer surfaces of the exciter <NUM> and the detector <NUM> of the first embodiment except the parts facing the tested object <NUM> may be covered with the covers <NUM> of ferromagnetic material. Even in such a modified case, the magnetic flux density in the tested object <NUM> can be enhanced as the effect of the covers <NUM> of ferromagnetic material.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a fourth embodiment of the present invention.

The eddy current flaw detection device according to the fourth embodiment has an exciter/detector <NUM> and a backside body <NUM> made of ferromagnetic material. The exciter/detector <NUM> of this embodiment is disposed in contact with the first flat surface <NUM>, and may have a structure similar to the structure of the first exciter/detector <NUM> of the second embodiment. The exciter/detector <NUM> is connected to the alternating current power source <NUM> and the detector circuit (not illustrated). The backside body <NUM> of ferromagnetic material is disposed opposite to the exciter/detector <NUM> sandwiching the tested object <NUM> therebetween, and in contact with the second flat surface <NUM>. The backside body <NUM> preferably covers all part of the second surface <NUM> which opposes to the exciter/detector <NUM> sandwiching the tested object <NUM>. The exciter/detector <NUM> has both functions of an exciter and a detector.

According to the fourth embodiment, alternating current is supplied from the alternating current power source <NUM> to the exciter/detector <NUM>, and variating magnetic field is formed in and around the tested object <NUM>. Thus, eddy current is induced in the tested object <NUM>, and a reactive magnetic field is formed. Owing to the backside body <NUM> of ferromagnetic material, the magnetic flux density in the tested object <NUM> is enhanced, and sensitivity of detection of the flaw <NUM> is enhanced.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a fifth embodiment of the present invention.

The fifth embodiment is a modification of the fourth embodiment. In the fifth embodiment, the exciter/detector <NUM> of the fourth embodiment is replaced with an exciter <NUM> and a detector <NUM>. The structures of the exciter <NUM> and the detector <NUM> of the fifth embodiment may be the same as those of the exciter <NUM> and the detector <NUM> of the first embodiment. In the fifth embodiment, the exciter <NUM> is disposed in contact with the first flat surface <NUM> of the tested object <NUM> while the detector <NUM> is disposed opposite to the tested object sandwiching the exciter <NUM> therebetween. The other structures are the same as those of the fourth embodiment.

According to the fifth embodiment, the magnetic flux density is enhanced owing to the backside body <NUM>, as the fourth embodiment, and sensitivity of detection of the flaw <NUM> is enhanced. Since the exciter <NUM> and the detector <NUM> are separated, as in the first embodiment, the exciter <NUM> and the detector <NUM> may have different structures and different specifications, and may have different designs with coil wire diameters, numbers of coil wire turns, shapes and sizes, etc., to fit respective purposes.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a sixth embodiment of the present invention.

The sixth embodiment is a modification of the fifth embodiment. In the sixth embodiment, a cover <NUM> made of ferromagnetic material is disposed covering the exciter <NUM> and the detector <NUM> which are structured and disposed in a similar way as in the fifth embodiment.

According to the sixth embodiment, the effects of the fifth embodiment are obtained, and the magnetic flux density in the tested object <NUM> can be further enhanced owing to the cover <NUM> made of ferromagnetic material. Then, sensitivity of detection of the flaw <NUM> can be further enhanced.

<FIG> is a schematic cross-sectional view illustrating a situation where flaw detection is conducted using an eddy current flaw detection device according to a seventh embodiment of the present invention.

The seventh embodiment is a modification of the fifth embodiment. In the seventh embodiment, the exciter <NUM> and the detector <NUM> are arranged parallel to each other both in contact with the first flat surface <NUM> of the tested object <NUM>. The backside body <NUM> of ferromagnetic material is disposed opposite to the exciter <NUM> and the detector <NUM> sandwiching the tested object <NUM> therebetween, and in contact with the second flat surface <NUM>. The backside body <NUM> preferably covers all part of the second surface <NUM> which opposes to the exciter <NUM> and the detector <NUM> sandwiching the tested object <NUM>. The other structures of the seventh embodiment are same as those of the fifth embodiment.

According to the seventh embodiment, in a similar way as in the fifth embodiment, the magnetic flux density in the tested object <NUM> can be enhanced owing to the backside body <NUM> of ferromagnetic material. Then, sensitivity of detection of the flaw <NUM> can be enhanced. In addition, since the exciter <NUM> and the detector <NUM> are separated, the exciter <NUM> and the detector <NUM> may have different structures and different specifications, and may have different designs with coil wire diameters, numbers of coil wire turns, shapes and sizes, etc., to fit respective purposes.

The features of the embodiments described above can be combined. For example, the cover <NUM> in the sixth embodiment can be added to the fourth and seventh embodiments.

While certain embodiments of the present invention have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the scope of the invention, which is as defined in the claims. The accompanying claims are intended to cover such forms or modifications as would fall within the scope of the claims.

Claim 1:
. An eddy current flaw detection device comprising:
an exciter (<NUM>) configured to induce eddy current in a tested object (<NUM>),
a detector (<NUM>) to detect a change in a reactive magnetic field generated by the eddy current in the tested object, the detector being separated from the exciter and located on the same side of the tested object,
a backside body made of ferromagnetic material disposed opposite side of the exciter and the detector sandwiching the tested object therebetween.