Eddy current testing of broken wires in thickly insulated cables using planer-3D hybrid coils

IF 4.9 3区工程技术 Q2 ENGINEERING, ELECTRICAL & ELECTRONIC

Sensors and Actuators A-physical Pub Date : 2025-09-10 DOI:10.1016/j.sna.2025.117049

Yiran Liu , Yongsheng Li , Yihua Kang , Yiru Xiao , Kai Wang , Bo Feng

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引用次数: 0

Abstract

As critical components in high-speed train systems, connecting cables endure harsh operating conditions—thermal cycling, overvoltage transients, and mechanical vibrations—which may induce wire breakage. Such failures present critical safety risks, potentially triggering operational interruptions, necessitating reliable non-destructive testing (NDT) methodologies for cable integrity evaluation. This paper proposes a flexible eddy current probe with a hybrid structure to detect broken wires in thickly insulated cables, such as those used in high-speed rail. The probe utilizes a flexible rectangular planar coil (FRPC) fabricated on a flexible printed circuit board (FPCB) as an exciter, integrated with differential three-dimensional (3D) race-track receiver coils. Combining the large field excitation capability of the planar coil and the high sensitivity of the 3D sensing coils significantly improves probe lift-off tolerance. Furthermore, an innovative asymmetric differential receiver structure effectively suppresses common-mode interference while overcoming dead zones and weak magnetic field gradients inherent in traditional symmetric differential methods. This enables reliable broken wire detection under significant lift-off conditions. Experimental results confirm the probe detects 0.18 mm diameter wire breaks at 8 mm lift-off with a 38.4 dB signal-to-noise ratio (SNR). Offering simplified system configuration, the probe provides an effective solution for NDT of in-service cables.

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利用平面-三维混合线圈对厚绝缘电缆断线进行涡流测试

作为高速列车系统的关键部件，连接电缆承受着恶劣的操作条件——热循环、过电压瞬变和机械振动——这些都可能导致电线断裂。这种故障会带来严重的安全风险，可能会导致作业中断，因此需要可靠的无损检测（NDT）方法来评估电缆的完整性。本文提出了一种混合结构的柔性涡流探头，用于检测高铁等厚绝缘电缆中的断线。探头利用柔性印刷电路板（FPCB）上制造的柔性矩形平面线圈（FRPC）作为激励器，与差分三维（3D）赛道接收器线圈集成。结合平面线圈的大场激励能力和三维传感线圈的高灵敏度，显著提高了探头的升力公差。此外，一种创新的非对称差分接收机结构有效地抑制了共模干扰，同时克服了传统对称差分方法固有的死区和弱磁场梯度。这可以在重要的升空条件下实现可靠的断线检测。实验结果证实，该探头检测到直径为0.18 mm的断丝，升距为8 mm，信噪比为38.4 dB。该探头简化了系统配置，为在役电缆的无损检测提供了有效的解决方案。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Sensors and Actuators A-physical 工程技术-工程：电子与电气

CiteScore

8.10

自引率

6.50%

发文量

630

审稿时长

49 days

期刊介绍： Sensors and Actuators A: Physical brings together multidisciplinary interests in one journal entirely devoted to disseminating information on all aspects of research and development of solid-state devices for transducing physical signals. Sensors and Actuators A: Physical regularly publishes original papers, letters to the Editors and from time to time invited review articles within the following device areas: • Fundamentals and Physics, such as: classification of effects, physical effects, measurement theory, modelling of sensors, measurement standards, measurement errors, units and constants, time and frequency measurement. Modeling papers should bring new modeling techniques to the field and be supported by experimental results. • Materials and their Processing, such as: piezoelectric materials, polymers, metal oxides, III-V and II-VI semiconductors, thick and thin films, optical glass fibres, amorphous, polycrystalline and monocrystalline silicon. • Optoelectronic sensors, such as: photovoltaic diodes, photoconductors, photodiodes, phototransistors, positron-sensitive photodetectors, optoisolators, photodiode arrays, charge-coupled devices, light-emitting diodes, injection lasers and liquid-crystal displays. • Mechanical sensors, such as: metallic, thin-film and semiconductor strain gauges, diffused silicon pressure sensors, silicon accelerometers, solid-state displacement transducers, piezo junction devices, piezoelectric field-effect transducers (PiFETs), tunnel-diode strain sensors, surface acoustic wave devices, silicon micromechanical switches, solid-state flow meters and electronic flow controllers. Etc...