Study on Orthogonal Fluxgate Sensor with High Sensitivity and Wide Dynamic Range for Magnetic Flux Leakage Testing
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Magnetic flux leakage (MFL) detection testing is a widely used inspection method for detecting pipeline defects by sensingthe magnetic flux leaked from defects. Various magnetic sensors have been studied for applications in MFL detection testing,with Hall sensors being the most commonly used because of their wide dynamic ranges. However, owing to their low sensitivity,Hall sensors exhibit limitations in detecting small defects. We developed an orthogonal fluxgate (OFG) sensor thatmaintains an appropriate dynamic range for an MFL magnetic environment while achieving high sensitivity. The OFG sensorconsists of an excitation coil with an Fe-based amorphous ribbon core and a pickup coil that detects the output voltage inducedby the excitation coil. We determined the sensitivity and dynamic range of the sensor by optimizing the shape of the core, whichis influenced by shape anisotropy. By adjusting the OFG sensor core length (2 mm, 4 mm, 6 mm) and thickness (50 μm, 150μm), we confirmed a tradeoff between sensitivity and dynamic range. As a result, we developed an OFG sensor with a dynamicrange of ±3 mT and a high sensitivity of 3,130 V/T. Furthermore, the application of the OFG sensor in MFL detection testingsuccessfully detected defects and confirmed its suitability for such applications.
Abstract
Magnetic flux leakage (MFL) detection testing is a widely used inspection method for detecting pipeline defects by sensingthe magnetic flux leaked from defects. Various magnetic sensors have been studied for applications in MFL detection testing,with Hall sensors being the most commonly used because of their wide dynamic ranges. However, owing to their low sensitivity,Hall sensors exhibit limitations in detecting small defects. We developed an orthogonal fluxgate (OFG) sensor thatmaintains an appropriate dynamic range for an MFL magnetic environment while achieving high sensitivity. The OFG sensorconsists of an excitation coil with an Fe-based amorphous ribbon core and a pickup coil that detects the output voltage inducedby the excitation coil. We determined the sensitivity and dynamic range of the sensor by optimizing the shape of the core, whichis influenced by shape anisotropy. By adjusting the OFG sensor core length (2 mm, 4 mm, 6 mm) and thickness (50 μm, 150μm), we confirmed a tradeoff between sensitivity and dynamic range. As a result, we developed an OFG sensor with a dynamicrange of ±3 mT and a high sensitivity of 3,130 V/T. Furthermore, the application of the OFG sensor in MFL detection testingsuccessfully detected defects and confirmed its suitability for such applications.