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A differential transformer-type electromagnetic sensor for weld seam tracking in submerged arc external welding of spiral welded pipes.

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Title: A differential transformer-type electromagnetic sensor for weld seam tracking in submerged arc external welding of spiral welded pipes.
Authors: Liu, Wenji1 (AUTHOR) liuwenji1981@126.com, Li, Bing1 (AUTHOR), Yue, Jianfeng1 (AUTHOR), Zhu, Peng1 (AUTHOR), Li, Qing1 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Feb2026, Vol. 142 Issue 7/8, p4029-4052. 24p.
Subjects: Differential transformers, Magnetic sensors, Magnetic flux, Submerged arc welding, Sensitivity analysis
Abstract: To address the challenge of automatic weld seam tracking in submerged arc external welding of spiral welded pipes—where ultra-narrow or virtually non-existent grooves and severe surface reflections complicate the process—a novel low-frequency excitation electromagnetic sensor based on differential transformer principles has been designed. This sensor comprises three sets of coils and an E-shaped magnetic core. By detecting the differential variation in magnetic flux distribution between the two magnetic paths on either side of the core, this sensor converts the transverse deviation of the weld seam into a differential signal of the induced electromotive force (EMF) in the secondary coils, with the two exhibiting an approximately linear relationship. Key parameters affecting its performance were analyzed based on electromagnetic field theory. Through COMSOL numerical simulations and comparative experiments, the influence mechanisms of parameters such as excitation current, air gap height, and coil turn ratio on sensitivity were revealed, thereby determining the optimal design parameters for the sensor. In tests simulating extreme conditions of spiral welded pipes (ultra-narrow grooves, reflective surfaces), the sensor demonstrated good performance, achieving a tracking accuracy of ± 0.2–0.5 mm, along with excellent robustness and test repeatability. This approach offers a highly reliable, low-cost technical solution to overcome the failure or stability limitations of existing laser vision, arc, and high-frequency eddy current sensors under extreme conditions. It lays the foundation for achieving high-quality automated welding in the external submerged arc welding of spiral welded pipes. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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Header DbId: egs
DbLabel: Engineering Source
An: 191452029
AccessLevel: 6
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PubTypeId: academicJournal
PreciseRelevancyScore: 0
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  Data: A differential transformer-type electromagnetic sensor for weld seam tracking in submerged arc external welding of spiral welded pipes.
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  Data: <searchLink fieldCode="AR" term="%22Liu%2C+Wenji%22">Liu, Wenji</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> liuwenji1981@126.com</i><br /><searchLink fieldCode="AR" term="%22Li%2C+Bing%22">Li, Bing</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Yue%2C+Jianfeng%22">Yue, Jianfeng</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhu%2C+Peng%22">Zhu, Peng</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Li%2C+Qing%22">Li, Qing</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Feb2026, Vol. 142 Issue 7/8, p4029-4052. 24p.
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  Data: <searchLink fieldCode="DE" term="%22Differential+transformers%22">Differential transformers</searchLink><br /><searchLink fieldCode="DE" term="%22Magnetic+sensors%22">Magnetic sensors</searchLink><br /><searchLink fieldCode="DE" term="%22Magnetic+flux%22">Magnetic flux</searchLink><br /><searchLink fieldCode="DE" term="%22Submerged+arc+welding%22">Submerged arc welding</searchLink><br /><searchLink fieldCode="DE" term="%22Sensitivity+analysis%22">Sensitivity analysis</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: To address the challenge of automatic weld seam tracking in submerged arc external welding of spiral welded pipes—where ultra-narrow or virtually non-existent grooves and severe surface reflections complicate the process—a novel low-frequency excitation electromagnetic sensor based on differential transformer principles has been designed. This sensor comprises three sets of coils and an E-shaped magnetic core. By detecting the differential variation in magnetic flux distribution between the two magnetic paths on either side of the core, this sensor converts the transverse deviation of the weld seam into a differential signal of the induced electromotive force (EMF) in the secondary coils, with the two exhibiting an approximately linear relationship. Key parameters affecting its performance were analyzed based on electromagnetic field theory. Through COMSOL numerical simulations and comparative experiments, the influence mechanisms of parameters such as excitation current, air gap height, and coil turn ratio on sensitivity were revealed, thereby determining the optimal design parameters for the sensor. In tests simulating extreme conditions of spiral welded pipes (ultra-narrow grooves, reflective surfaces), the sensor demonstrated good performance, achieving a tracking accuracy of ± 0.2–0.5 mm, along with excellent robustness and test repeatability. This approach offers a highly reliable, low-cost technical solution to overcome the failure or stability limitations of existing laser vision, arc, and high-frequency eddy current sensors under extreme conditions. It lays the foundation for achieving high-quality automated welding in the external submerged arc welding of spiral welded pipes. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.1007/s00170-026-17414-0
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      – Code: eng
        Text: English
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        PageCount: 24
        StartPage: 4029
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      – SubjectFull: Differential transformers
        Type: general
      – SubjectFull: Magnetic sensors
        Type: general
      – SubjectFull: Magnetic flux
        Type: general
      – SubjectFull: Submerged arc welding
        Type: general
      – SubjectFull: Sensitivity analysis
        Type: general
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      – TitleFull: A differential transformer-type electromagnetic sensor for weld seam tracking in submerged arc external welding of spiral welded pipes.
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            NameFull: Liu, Wenji
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            NameFull: Li, Bing
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            NameFull: Yue, Jianfeng
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            NameFull: Zhu, Peng
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            NameFull: Li, Qing
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            – D: 01
              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
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              Value: 142
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