Method and apparatus for magnetically detecting defects in an object with compensation for magnetic field shift by means of a compensating coil

• US 5,512,821 A
• Filed: 02/01/1993
• Issued: 04/30/1996
• Est. Priority Date: 06/04/1991
• Status: Expired due to Fees

• Current Assignee: NKK Corporation (JFE Holdings Incorporated)
• Original Assignee: NKK Corporation (JFE Holdings Incorporated)
• Inventors: Takenaka, Masaki, Inaba, Mamoru, Takeoshi, Atsuhisa, Maki, Hiroshi, Ando, Seigo, Iwanaga, Kenichi, Matsufuji, Yasuhiro
• Primary Examiner(s): O'Shea, Sandra L.
• Assistant Examiner(s): PATIDAR, JAY M
• Application Number:
  US07/974,585
• Time in Patent Office: 1,184 Days
• Field of Search: 324/225, 324/234, 324/235-243, 324/262, 324/226, 324/227, 324/229-231, 324/261, 361/143, 361/146, 361/267, 361/149, 72/10, 72/11
• US Class Current: 324/225
• CPC Class Codes: G01N 27/82 for investigating the presence of flaws

Abstract

A magnetic detector includes a magnetizer generating a magnetic field; a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to the magnetic field; a low-pass filter for extracting a low-frequency signal component contained in the signal output by the magnetic sensor, the low-frequency signal component being indicative of a floating flux which crosses the magnetic sensor and is a result of the object moving through the magnetic field; an amplifier for amplifying the extracted low-frequency signal component; a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out the floating flux crossing the magnetic sensor; a high-pass filter for extracting a signal resulting from the magnetically defective portion and contained in the signal that is output by the first magnetic sensor; an output amplifier for amplifying a signal output by the high-pass filter to produce a defect signal; a second magnetic sensor located near the first magnetic sensor, for detecting a component of the magnetic field which is parallel to the surface of the object; an amplifier control circuit for controlling an amplification factor of the output amplifier in accordance with a signal from the second magnetic sensor; and a magnetizer control circuit for controlling the intensity of the magnetic field generated by the magnetizer, in accordance with a signal output by the second magnetic sensor.

Claims

1. A magnetic detector comprising:

means for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field and for producing a signal corresponding thereto;

a low-pass filter for extracting a low-frequency signal component contained in said signal that is output by the magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses said magnetic sensor and which is a result of the object moving through said magnetic field;

an integrator for integrating the low-frequency signal component extracted by the low-pass filter;

an amplifier for amplifying the low-frequency signal component integrated by the integrator; and

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said magnetic sensor.

2. A magnetic detector according to claim 1, wherein said compensating coil is wound in surrounding relation to an outer circumferential surface of said magnetic sensor.

3. A magnetic detector comprising:

means for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field, said object having a surface;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal that is output by said first magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object; and

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by said second magnetic sensor.

7. A magnetic detector according to any one of claims 3, 4, 5 and 6, wherein said first magnetic sensor for detecting said leakage flux is oriented to detect a component of said leakage flux which is orthogonal to the surface of said object.

8. A magnetic detector according to any one of claims 3, 4, 5 and 6, wherein said first magnetic sensor for detecting said leakage flux is oriented to detect a component of said leakage flux which is parallel to the surface of said object.

4. A magnetic detector comprising:

a magnetizer for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field generated by said magnetizer, said object having a surface;

said first magnetic sensor outputting a first output signal that is indicative of the leakage flux of the magnetically defective portion of the object;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which contained in the signal that is output by said first magnetic sensor;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object;

an output amplifier coupled to receive a signal output by the high pass filter and for outputting an amplified signal as a defect signal; and

magnetizer control means for controlling intensity of an said magnetic field generated by said magnetizer, in accordance with a signal output by the second magnetic sensor.

5. A magnetic detector comprising:

means for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field and for producing a signal corresponding thereto, said object having a surface;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the first magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses said first magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by said low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said first magnetic sensor, said compensating coil being located near said first magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal that is output by said first magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object; and

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by the second magnetic sensor.

9. A magnetic detector according to claim 5, wherein said compensating coil is wound in surrounding relation to an outer circumferential surface of said first magnetic sensor.

6. A magnetic detector comprising:

a magnetic for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field generated by a magnetizer and for producing a signal corresponding thereto, said object having a surface;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the first magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses said first magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by said low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said first magnetic sensor, said compensating coil being located near said first magnetic sensor;

a high-past filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal output by said first magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object; and

magnetizer control means for controlling the intensity of the magnetic field generated by said magnetizer, in accordance with a signal output by the second magnetic sensor.

10. A magnetic detector according to claim 6, wherein said compensating coil is wound in surrounding relation to an outer circumferential surface of said first magnetic sensor.

11. A magnetic detector comprising:

means for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field and for producing a signal corresponding thereto;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses said magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by said low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and contained in the signal that is output by said magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal; and

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by said magnetic sensor.

13. A magnetic detector according to claims 11 or 12, wherein an integrator is connected between said low-pass filter and said amplifier.

12. A magnetic detector comprising:

a magnetizer for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field generated by said magnetizer and for producing a signal corresponding thereto, said object having a surface;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses said magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by said low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and contained in the signal that is output by said magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal; and

magnetizer control means for controlling the intensity of the magnetic field generated by said magnetizer, in accordance with a signal output by the magnetic sensor.

14. A magnetic detector comprising:

a magnetizer for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to a magnetic field generated by said magnetizer;

magnetizer control means for controlling the intensity of the said magnetic field generated by said magnetizer, in accordance with a signal output by said second magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in a signal output by said magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal; and

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by said magnetic sensor.

15. A magnetic detector according to claim 14, wherein said object has a surface which extends in a plane, and said magnetic sensor for detecting said leakage flux is oriented to detect a component of said leakage flux which is parallel to said plane.

16. A magnetic detector comprising:

means for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field and for producing a signal corresponding thereto;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses the magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by the low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal that is output by said magnetic sensor;

a speed detector for detecting a speed at which said object moves relative to said magnetic sensor; and

frequency control means for controlling a pass frequency of said high-pass filter in accordance with the speed detected by said speed detector.

17. A magnetic detector according to claim 16, wherein said object has a surface which extends in a plane, and said magnetic sensor is oriented to detect a component of the leakage flux resulting from the magnetically defective portion of said object, which is parallel to said plane, and said compensating coil is wound in surrounding relation to an outer circumferential surface of said magnetic sensor.

18. A magnetic detector according to claim 16, further comprising;

a roll contacting said object for changing a direction in which said object is moving, and wherein said object is a moving strip; and

wherein said means for generating a magnetic field includes a magnetizer opposing a portion of said object which contacts an outer circumferential surface of said roll, for generating said magnetic field.

19. A magnetic detector according to claim 18, wherein said magnetizer has a pair of magnetic poles which oppose the object contacting the outer circumferential surface of said roll, and said magnetic sensor is arranged between the magnetic poles of said magnetizer.

20. A magnetic detector according to claim 18, wherein said magnetizer has a pair of magnetic poles which oppose a portion of said roll which is to contact said object, and said magnetic sensor is arranged between the magnetic poles of said magnetizer.

21. A magnetic detector according to claim 16, wherein said compensating coil is wound in surrounding relation to an outer circumferential surface of said magnetic sensor.

22. A magnetic detector comprising:

means for generating a magnetic field;

a magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field and for producing a signal corresponding thereto;

a low-pass filter for extracting a low-frequency signal component contained in said signal output by the magnetic sensor, said low-frequency signal component being indicative of a floating flux which crosses the magnetic sensor and which is a result of the object moving through said magnetic field;

an amplifier for amplifying the low-frequency signal component extracted by the low-pass filter;

a compensating coil excited by the amplified low-frequency signal component output by the amplifier, for generating a magnetic flux which cancels out said floating flux crossing said magnetic sensor;

said means for generating said magnetic field comprising a magnetizer arranged such that a pair of magnetic poles oppose said object;

said magnetic sensor being arranged on a line connecting said magnetic poles;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal that is output by said magnetic sensor;

a speed detector for detecting a speed at which said object moves relative to said magnetic sensor; and

frequency control means for controlling a pass frequency of said high-pass filter in accordance with the speed detected by said speed detector.

23. A magnetic detector according to claim 22, wherein said compensating coil is wound in surrounding relation to an outer circumferential surface of said magnetic sensor.

24. A magnetic detector comprising:

means for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field, said object having a surface;

a high-pass filter for extracting a signal resulting from the magnetically defective portion and which is contained in the signal that is output by said first magnetic sensor;

an output amplifier for amplifying a signal output by said high-pass filter and for outputting the amplified signal as a defect signal;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object;

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by said second magnetic sensor;

a reference signal generating circuit for generating a reference signal corresponding to a reference amplification factor; and

a division circuit connected between said second magnetic sensor and said output amplifier for detecting that component of said magnetic field which is parallel to the surface of said object, and for dividing a signal output by said second magnetic sensor by said reference signal for controlling amplification of said output amplifier.

25. A magnetic detector according to claim 24, wherein a compensating coil is wound in surrounding relation to an outer circumferential surface of said first magnetic sensor.

26. A magnetic detector comprising:

a magnetizer for generating a magnetic field;

a first magnetic sensor for detecting a leakage flux resulting from a magnetically defective portion of an object moving in and relative to said magnetic field generated by said magnetizer, said object having a surface;

said first magnetic sensor outputting a first output signal that is indicative of the magnetically defective portion of the object;

a second magnetic sensor located near said first magnetic sensor, for detecting a component of said magnetic field which is parallel to the surface of said object;

magnetizer control means for controlling an intensity of said magnetic field generated by said magnetizer, in accordance with a signal output by the second magnetic sensor;

a high-pass filter for extracting a signal resulting from the magnetically defective portion of the object and which is contained in the first output signal output by said first magnetic sensor;

an output amplifier for amplifying the first signal output by said first magnetic sensor and for outputting an amplified signal as a defect signal; and

amplifier control means for controlling an amplification factor of said output amplifier in accordance with a signal output by said second magnetic sensor for detecting said component of said magnetic field which is parallel to the surface of said object.

27. A magnetic detector according to claim 26, wherein the first output signal output from the first magnetic sensor is amplified by an amplifier.

28. A magnetic detector according to claim 26, wherein a compensating coil is wound in surrounding relation to an outer circumferential surface of said first magnetic sensor.