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.

中文翻译：

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金属线焊缝的实时参数评估：3-D 模拟和实验验证

本文的重点是使用环形线圈涡流传感器对高速高端拉制金属线材的焊缝进行实时表征。重点放在评估焊缝长度及其稳定性跨度上，特别参考了通过简易非线性回归工具进行的信号模式识别。实施了 3-D CIVA 模拟电磁测试模块来评估系统的理论预期响应。使用 EC 数据的信号处理研究了焊缝的定性和定量分析。在第 1 和第 8 道焊接位置，模拟结果和实验结果之间的焊缝跨度百分比偏差分别约为 1.6% 和 12.5%。这表明与较大直径的焊丝（第 1 次焊丝）相比，较小直径焊丝（第 8 次焊丝）上的焊缝不均匀。在理论和实验结果之间观察到良好的一致性。从应用的角度来看，这些发现表明实现更高效率与可靠质量控制相结合的重要性。所提出方法的在线实现满足两个要求；检测精度和检测速度。