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A Novel Forging Hammerhead Displacement Detection System Based on Eddy Current Sensor [Sensors & Transducers (Canada)](Sensors & Transducers (Canada) Via Acquire Media NewsEdge) Abstract: For strong vibration, high temperature and dust in the forging site, a displacement detection system based on eddy current sensor is proposed to monitor the size of forgings online in this paper. Equidistant grooves are machined in the vertical direction on the side of hammerhead and the eddy current sensor probe is installed opposite the grooves in the rack. The hammerhead displacement can be obtained with output voltage signal according to hammerhead moving process. The feasibility of the proposed system is determined based on the magnetic field characteristics analysis of groove specimen surface using Ansoft software. The mathematical model of the displacement measurement is established through experiments on the processed metal plate. Experimental results show that the novel displacement detection system is feasible and accurate position of forging hammerhead can be obtained. Copyright © 2014 IFSA Publishing, S. L. Keywords: Hydraulic forging hammer, Eddy current sensor, Displacement measurement. (ProQuest: ... denotes formulae omitted.) 1. Introduction This Computer numerical control is an important development direction of forging equipment. And forgings size monitoring is the foundation of forging hammer automation [1]. Because of strong vibration, high temperature and dust in the forging site, it is difficult to monitor forgings size in the forging industry. But there are few papers focused on the problem. The paper described a rope displacement sensor, which detected hammer displacement by turning the encoder driven through the ropes [2]. However, this sensor has disadvantages of slow reciprocating and short life. Grating displacement sensor was used to detect hammer displacement [3]. Although the isolation and damping measures are taken, it is difficult to ensure the stability and accuracy of the sensor because of strong impact and dust. LASCO, which is a company of advanced forging equipment products, designs a hammer head displacement detection system based on a capacitive displacement sensor in hammer rod. And the forgings size can be measured with a very high precision [4]. But this method has high technology requirements, which makes it difficult to be widely used. Due to huge hitting force, it's better to use non-contact detection method to ensure reliability of the measurement [5]. According to eddy current sensor's advantages of fast response, high sensitivity, anti-interference ability, a novel detection system based on eddy current sensor is proposed to achieve forgings size online. This system has advantages of non-contact, large range and no sensor is installed in the hammer head, which greatly improve detection reliability. 2. The Principles of the Proposed Forging Hammerhead Displacement Detection System 2.1. System Design This paper presents a linear displacement measurement method based on eddy current sensor. Equidistant grooves are machined in a vertical direction on the side of hammerhead as a scale ruler and the eddy current sensor probe is installed opposite the grooves. When the hammerhead moves, movement of grooves causes changes of sensor probe lift-off, and the sensor output voltage signal regularly. After denoising the signal with wavelet, nonlinear fitting methods are used to establish mathematical model between the hammer moving displacement and the voltage signal. Finally, the hammerhead displacement can be calculated by output voltage signal in hammerhead moving process. 2.2. The Principle of Eddy Current Sensor The principle diagram of eddy current displacement sensor is shown in Fig. 1. A highfrequency magnetic field generated by passing a high frequency current distributes near the sensor head coil. When a metal target is in the magnetic field, electromagnetic induction causes an eddy current perpendicular to the magnetic flux passage to flow on the surface of the target. This changes the impedance of the sensor head coil. Eddy current sensors measure the distance between the sensor head and target, based on this change in oscillation status. 2.3. Simulation In order to analyze the characteristics of the sensor output signal with the hammerhead, Ansoft Maxwell is used to simulate magnetic field on the surface of groove specimen. Simulation parameters are chosen as follows: the cross-section diameter of the coil is 1 mm, coil diameter is 11 mm, and the material is copper. The driving current is 0.5 A in amplitude, 1 MHz in frequency, and the material of specimen is 45# steel [6]. Specimen size is designed as follows: the groove is 15 mm in width and spacing, 40 mm in length, 1.5 mm in depth and the sensor probe lift-off is 2.5 mm, as shown in Fig. 2. To make it easy to analyze the result, the position where center of the coil and the edge of the groove are tangent defined as the coordinate zero. The magnetic field vector and distribution on the surface of specimen are given with simulating the magnetic field on the specimen. In Fig. 3, when the coil is located above the center of step (x=7.5 and x=37.5), the induced magnetic is strongest in the whole process. When the coil is located above the center of groove (x=22.5), the induced magnetic is least. When the coil is located elsewhere the induced magnetic is between the maximum and minimum. Based on the analysis and relationship between induced magnetic and sensor output voltage, the output voltage signal changes periodically in the process of hammerhead movement. As described in the paper [7], the relationship between eddy size on specimen surface and diameter of the coil is 2R= 1.39D; 2i=0.525D, where D is the probe diameter (D is 12 mm in this paper), r is the inner radius of eddy size and R is the outer radius of eddy size. Therefore, in order to obtain the continuous changes of output voltage signal, the groove width X should satisfy the inequality 0.525D<A,<1.39D. Namely, X should be between 8 and 16 mm. Through experiments and analysis, finally the width and spacing of the groove which designed are both 15 mm. According to the analysis, probe lift-off also has great effect on sensor output signal [8]. In order to get a better output signal, a series of magnetic field magnitude curves are drawn for different lift-off. Probe lift-off is chosen from 1-4 mm and the spacing is 0.5 mm. Line 1 is the magnetic field strength curve, when the probe lift-off height is 1 mm. The probe lift-off height of line 7 is 4 mm, as shown in Fig. 4. Through observation and comparison, when the lift-off is between 1.5 ~ 2.5 mm, the output voltage signal is similar to the sinusoidal. Finally, the probe lift-off is 2.0 mm, which makes the system a better resolution. 3. Experimental System Designs Physical map of specimen is shown in Fig. 5. The groove is 15 mm in width and spacing, 40 mm in length, 1.5 mm in depth. The sensor probe fixed on the rail is opposite the specimen, and the space between sensor probe and specimen is 2.5 mm. The type of the eddy current sensor is RP6612 whose parameters are shown in Table 1. The sensor output signal is collected by Advantech DAQ USB-4704 in real time. Fig. 6 shows the waveform diagram of the sensor output voltage, when the probe is moving parallel to the specimen. 4. Signal Processing and Displacement Calculation 4.1. Signal Processing There is serious noise in the output signal. To improve the SNR and extract feature information, Morlet wavelet method is selected to preprocess the signal. Morlet wavelet has advantages of high resolution in time and frequency domain, and it can reduce signal distortion [9]. From Fig. 7, the denoised signal is smoother than the original signal significantly and SNR is improved, which make it easy to extract the feature amount. 4.2. Displacement Calculation 4.2.1. Peak Detection The hammer displacement consists of two parts. One is the complete cycles of the groove scale. The other is the relative displacement of the probe in a cycle. ...(1) where S is the total displacement relative to zero, SI is the displacement offset of the probe, S2 is the probe relative displacement in a cycle. As can be known from the section 2, peaks and troughs correspond to the middle of grooves and steps. So Equation (1) can be expressed as S =NxA.+S2, where N is the sum of peaks and troughs in output signal, X is the width of groove. Therefore, the sum of peaks and troughs it is a key to calculating the hammerhead displacement. Peaks detection algorithm consists of setting threshold value, dividing data and maxima value judgment; Algorithm flowchart is shown in Fig. 9. First of all, data is assigned to the array A[i]. Then, after setting the threshold, the data above the threshold is put into specific array. Finally, the method for calculating extreme value is used to get the number of peaks. The number of troughs can be obtained in the similar way. N=Nt +Nb, where Nt is the number of peaks, Nb is the number of roughs. Then the value of SI can be calculated as ...(2) 4.2.1. Data Fitting Method 1: sinusoidal fitting The relationship between probe displacement in a cycle and output voltage signal is nonlinear. In order to establish the mathematical model of displacement and the output voltage signal, sinusoid is used to fit the corresponding output voltage signal. Fig. 10 shows the interface of the output voltage, when the probe slides parallel to the specimen three times. The solid line in Fig. 10 indicates the fitting sinusoid based on experimental data. From Fig. 10, the output signal is sensitive to the location of the probe. When the probe moves from the middle of groove to the next, the output voltage changes from maximum to minimum. The period of fitting sinusoidal is 30 mm, which equals to the sum of the width of groove and step. With defining probe position as abscissa and output voltage as ordinate, Cartesian coordinates are built to describe the output voltage waveform. Point a is the minimum and point d is the maximum. The sketch of probe position and output signal is shown in Fig. 11. In this coordinate system, the relationship between the relative position of probe and output voltage is ...(3) where A is the amplitude of the sinusoid, b is the phase, c is the constant, and T is the sinusoidal cycle. Xj is the relative position of probe, Uj is the output voltage. A= (ul-u0)/2, c= (ul+ u0)/2, T is 30 mm. The parameters are substituted into equation 3 and by using methods of coordinate translation Equation (1) can be deformed into ...(4) The Xj can be expressed as ...(5) when the output voltage values are in rising interval, S2 can be written as ...(6) Otherwise, S2 is written as ...(7) In order to express the result in one formula, the flag bit P is selected. If the output voltage values are in rising interval, P is zero, which equals to the last extreme point is trough. Otherwise, P is 1. Then, S2 can be expressed as ...(8) Method 2: least-squares fitting Least-squares fitting method is widely used in nonlinear fitting. The basic principle of the least square method can be described as follows [10]: for given data, a function P(x) which makes the squares of r¿ = p(x¿) - yi least needs to be solved. Scilicet ... Function p (x) is so called fitting function or least squares solution. With fitting the relative displacement in a cycle and sensor output voltage, the least squares polynomial is ... where y is the output voltage; x is the relative displacement in a cycle, which equals to S2. The fitting curve is shown in Fig. 12. In the actual detection process, according to the least squares fitting polynomial, the relative displacement can be calculated by sensor output voltage, which makes it possible to monitor the displacement of hammerhead online. 5. Results and Discussions In order to verify the system accuracy, the probe fixed on the rail slides parallel to the groove specimen repeatedly. The position, where probe and the edge of groove is tangent, is defined as initial zero. After experiments, the displacements measured by this system are compared with the results measured by magnetic grid sensor whose accuracy is lum and measurements are treated as actual value. Comparative results between measured displacement and real displacement are shown in Table 2. As shown in Table 2, measured errors are small in this system. The average error of sinusoidal fitting is 0.454 mm, and the average error of least-squares fitting is 0.245 mm. The maximum error of leastsquares fitting is 0.36 mm and minimum error is 0.14 mm, which indicates the method of leastsquares fitting has higher precision. When the measurement range increases, the errors keep small and have no tendency to increase, indicating a wide range of displacement can be measured accurately in this system. 6. Conclusion A novel displacement detection system based on eddy current sensor is proposed in the paper. Feature extraction and nonlinear fitting methods are used in the hammerhead displacement detection algorithm. This system has advantages of non-contact, large range and fast response. This paper provides a new idea for detecting linear displacement, which is significant to hammer automation. References [1]. P. Bodurov, T. Penchev, Industrial rocket engine and its application for propelling of forging hammers, Journal of Materials Processing Technology, 161, 3, 2005, pp. 504-508. [2]. Chu Y. J., Application of cable-extension displacement transducer on 20 MN fast forging press, Special Steel Technology, 3,2011, pp. 52-55. [3]. Chen Q. Z., The application of grating-displacement sensor in position servo system and its error analysis, Machine Tool & Hydraulics, 36, 8, 2008, pp. 217-219. [4]. Ruger H. D., The current status and future development of hydraulic forging hammer, Chinese Journal of Mechanical Engineering, 51, 3, 2012, pp. 304-308. [5]. Tsutomu M., Method for identifying type of eddycurrent displacement sensor, IEEE Transactions on Magnetics, 47, 10,2011, pp. 3554-3557. [6]. Fan Mengbao, Huang Pingjie, Ye Bo, Analytical modeling for transient probe response in pulsed eddy current testing, NDT and E International, 42, 5, 2009, pp. 276-383. [7]. G. Y. Tian, A. Sophian, Defect classification using a new feature for pulsed eddy current sensors, NDT andE International, 38, 1,2005, pp. 77-82. [8]. Petr Shkatov, Combining eddy-current and magnetic methods for the defectoscopy of ferromagnetic materials, Nondestructive Testing and Evaluation, 28, 2,2013, pp. 155-165. [9]. Neville, Stephen, Dimopoulos, Wavelet denoising of coarsely quantized signals, IEEE Transactions on Instrumentation and Measurement, 55, 3, 2006, pp. 892-901. [10]. Sung Joon, Wolfgang Rauh, Hans-Jurgen, Leastsquares orthogonal distances fitting of circle, sphere, ellipse, hyperbola, and parabola, The Journal of the Pattern Recognition Society, 34, 2001, pp. 2283-2303. ZHANG Chun-Long, CHEN Zi-Guo Department of Electronic Engineering, Nantong Vocational College, Nantong 226007, China E-mail: [email protected] Received: 9 June 2014 /Accepted: 31 July 2014 /Published: 31 August 2014 (c) 2014 IFSA Publishing, S.L. |