Automated Deformation Detection System for Tubes and Rods in Manufacturing Industries Using Quasi Digital Sensors

This paper reports the feasibility study of developing an automatic deformation detection system. This system detects the out of roundness or deformation on the surface of cylindrical tubes or rods during mass production for specified application with better quality control. It has been identified that there is need for an automated system that will help tube or rod manufacturing industries to detect deformation in the end products to meet quality assurance goals of the industry. The system that has been reported in this paper uses an out of roundness or deformation detection sensor which works on the principle of the magnetic induction variation in terms of frequency for detecting any bulging or deformation on the surface of the rod. This system has been tested with a cylindrical rod with non-uniform surface and can detect the minimum deformation of 5 microns. It has been observed that there is feasibility for developed system to be used to detect a minimum deformation of 1 micron if the sensor design is further fine-tuned. This system is advantageous to the manufacturing industry for cost effective and timely production.