Real-Time Parametric Evaluation of Weld in Metallic Wires: A 3-D Simulation and Experimental Validation

This paper is focused on the real-time characterization of weld in high speed high-end drawn metallic wires using encircling coil eddy current sensor. Emphasis was laid on the evaluation of weld-length and its span of stability with a special reference to signal pattern recognition through the improvised non-linear regression tool. A 3-D CIVA simulation electromagnetic testing module was implemented to evaluate the theoretical expected response of the system. The qualitative and quantitative analysis of welds was studied using signal processing of EC data. The percentage deviations in weld-span between simulated and experimental results were found to be around 1.6% and 12.5% at welding location of 1st and 8th pass respectively. This demonstrates the non- uniformity of the weld on relatively smaller diameter wire (8th pass) as compared to the larger diameter wire (1st pass). A good agreement was observed between the theoretical and experimental results. From the applications perspective, these findings indicate the importance on achieving higher efficiency combined with reliable quality control. On-line implementation of the proposed method satisfies both the requirements; detection accuracy and detection speed.