Geometric Optimization of Eddy-Current Sensor Coils for Enhanced Sensitivity: A Computational and Experimental Approach

Eddy Current Testing (ECT) is a common non-destructive method for detecting flaws in conductive materials such as aluminum and copper, and its detection sensitivity largely depends on the probe coil design. Past studies often lack systematic optimization, leading to suboptimal coils with high resistance and low inductance. This research optimizes transmitter and receiver coils in an ECT system through computational modeling and physical validation to enhance detection capabilities. A Python simulation evaluated key parameters—including the number of turns, coil length, radius, observation distance, and applied current—to compute the resulting magnetic fields and voltages. The computational model was then validated against physical measurements obtained with an LCR meter. The optimal transmitter has 300 turns over 10 layers, with diameters of 6 cm and 7.6 cm, an inductance of 2.59 mH, and a resistance of 1.1 Ω, producing the strongest magnetic field. The receiver uses a 490-turn coil (7.32 mH, 6.4 Ω) to maximize voltage, while a two-coil series reduces resistance to 4.7 Ω and inductance to 2.5 mH for stability. This approach establishes a robust, optimized coil design framework, demonstrating that precise parameter adjustments significantly improve electromagnetic properties and overall signal stability in ECT sensing systems.