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Modeling of inductive coil geometry for gap position measurement
University West, Department of Engineering Science, Research Enviroment Production Technology West. GKN Aerospace Engine Systems, Trollhättan, Sweden. (PTW)ORCID iD: 0000-0003-3697-1995
2018 (English)In: Procedia Manufacturing, E-ISSN 2351-9789, Vol. 25, p. 103-110Article in journal (Other academic) Published
Abstract [en]

Finite element modelling of high frequency inductive coils and metal plates was used to investigate the impedance response to a narrow gap between the plates. The model was used to predict distance sensitivity for both coil-to-gap and coil-to-plate. Different coil axis orientations, along and across the gap and normal to the plate, were modeled, as well as different coil lengths. The model can be used to predict the working range and select orientation and geometry of inductive seam tracking probes with zero gap capability for precision laser beam welding. Different materials, thicknesses and frequencies can be used.

Place, publisher, year, edition, pages
2018. Vol. 25, p. 103-110
Keywords [en]
Seam tracking, FEM, Inductive
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-12847DOI: 10.1016/j.promfg.2018.06.063Scopus ID: 2-s2.0-85065665097OAI: oai:DiVA.org:hv-12847DiVA, id: diva2:1243338
Conference
8th Swedish Production Symposium (SPS 2018), Stockholm, Sweden, May 16-18, 2018
Funder
Knowledge Foundation, 20140130
Note

Del av specialnumret Proceedings of the 8th Swedish Production Symposium (SPS 2018) Redaktörer: M. Onori, L. Wang, X. V. Wang och W. J

Available from: 2018-08-31 Created: 2018-08-31 Last updated: 2019-06-05Bibliographically approved
In thesis
1. An inductive gap measurement method for square butt joints
Open this publication in new window or tab >>An inductive gap measurement method for square butt joints
2019 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

A recent method in aero engine production is to fabricate components from smaller pieces, rather than machining them from large castings. This has made laser beam welding popular, offering high precision with low heat input and distortion, but also high productivity. At the same time, the demand for automation of production has increased, to ensure high quality and consistent results. In turn, the need for sensors to monitor and control the laser welding process is increasing. In laser beam welding without filler material, the gap between the parts to be joined must be narrow. Optical sensors are often used to measure the gap, but with precise machining, it may become so narrow that it is difficult to detect, with the risk of welding in the wrong position. This thesis proposes the use of an inductive sensor with coils on either side of the gap. Inducing currents into the metal, such a sensor can detect even gaps that are not visible. The new feature of the proposal is based on using the complex response of each coil separately to measure the distance and height on both sides of the gap, rather than an imbalance from the absolute voltage of each coil related to gap position. This extra information allows measurement of gap width and alignment as well as position in a working range of about 1 mm around the gap, and decreases the influence from variation in gap alignment to the position measurement. The sensor needs to be calibrated with a certain gap width and height alignment. In real use, these will vary, causing the sensor to be less accurate. Using initial estimates of the gap parameters from the basic sensor, a model ofthe response can be used to estimate the measurement error of each coil, whichin turn can be used for compensation to improve the measurement of the gap properties. The properties of the new method have been examined experimentally, using aprecise traverse mechanism to record single coil responses in a working range around a variable dimension gap, and then using these responses to simulate atwo coil probe. In most cases errors in the measurement of weld gap position and dimensions are within 0.1 mm. Different coil orientations were studied using numerical simulation, and validated in experiments using a two coil probe. The influence of scratches, chamfers and variation in plate thickness was investigated at different frequencies.

Place, publisher, year, edition, pages
Trollhättan: University West, 2019. p. 60
Series
PhD Thesis: University West ; 30
Keywords
Eddy current; Seam tracking; Measurement; Laser beam welding; gap geometry
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
urn:nbn:se:hv:diva-13841 (URN)978-91-88847-33-1 (ISBN)978-91-88847-32-4 (ISBN)
Public defence
2019-05-28, F104 Albertssalen, Högskolan Väst, Trollhättan, 10:00 (English)
Opponent
Supervisors
Available from: 2019-05-10 Created: 2019-05-10 Last updated: 2019-12-10Bibliographically approved

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Svenman, Edvard

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