CN103760222A - Mining steel wire rope online detection device and method based on giant magnetoresistance sensor array - Google Patents
Mining steel wire rope online detection device and method based on giant magnetoresistance sensor array Download PDFInfo
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Abstract
The invention discloses a mining steel wire rope online detection device and a mining steel wire rope online detection method based on a giant magnetoresistance sensor array. The device comprises a probe, a signal conditioning module, a data acquisition card, a computer and a positioning module. The method comprises the following steps: magnetizing the steel wire rope by using an excitation device in the probe, and detecting a leakage magnetic field generated by damage by using a giant magnetoresistance sensor in the probe; processing an output signal of the probe by using the signal conditioning module, and inputting the processed output signal into the computer together with a signal of the positioning module through the data acquisition card; displaying the probe signal in real time on the computer, and comparing the probe signal with a preset threshold value to determine whether damage exists on the steel wire rope to be detected; if the probe signal is higher than the preset threshold value, indicating that damage exists on the steel wire rope to be detected, further determining the type and size of the damage, and determining a damage position according to the signal of the positioning module. The detection device and the detection method have the outstanding characteristics that by adopting the probe consisting of the giant magnetoresistance sensor array, the sensitivity of the detection device can be increased remarkably. The device and the method have good application prospects in damage detection of the mining steel wire rope.
Description
Technical field
The present invention relates to a kind of pit rope on-line measuring device and method based on giant magnetoresistance sensor array, belong to mining machinery equipment field.
Background technology
Wire rope has a very wide range of applications in mining machinery equipment as system core member, have that good bending property, intensity are high, good springiness, the ability that withstands shocks are strong, from advantages such as heavy and light, stable working.Yet, along with the increase of wire rope active time, there will be the various damages such as fatigue, corrosion, fracture of wire.The damage type of wire rope is various, and the generation of damage and development be interrelated and impact, and as the damage of wire rope corrosion meeting unstable wear, and wearing and tearing can cause fracture of wire, and corrosion sometimes also can directly cause fracture of wire.If can not obtain in time the degree of injury of wire rope and take corresponding measure, may cause wire cable rupture, cause security incident, very harmful.Therefore, design and develop pit rope pick-up unit, wire rope is carried out to online detection and assessment, to ensureing that Safety of Coal Mine Production is significant.
Wire rope is a kind of ferrimagnet, and the most frequently used detection method is leakage method.The principle that leakage method detects wire rope is, utilize excitation unit, along wire rope axial direction, wire rope is carried out to excitation, once wire rope exists defect, can produce leakage field on wire rope surface, then apply Magnetic Sensor detection of leaks magnetic field, thereby reach the object that detects damage of steel cable.The most frequently used Magnetic Sensor is Hall element, coil, anisotropic magnetoresistive sensor etc. at present.Hall element cost is low, be widely used, but the remolding sensitivity of Hall element is lower, skew large, temperature stability is low; That coil is made is simple, cost is low, but aspect static state or low frequency magnetic field measurement scarce capacity; Anisotropic magnetoresistive sensor remolding sensitivity is higher, and response is fast, but that anisotropic magnetoresistive sensor can be measured magnetic field range is little, poor anti jamming capability.
First the Fil professor research group of Paris, FRA university in 1988 has found magnetoresistance effect in Fe/Cr multilayer film, because the change rate of magnetic reluctance of its generation is much larger than the magnetoresistance based on anisotropic, is therefore called as giant magnetoresistance effect.The Magnetic Sensor that exploitation has high stability, high sensitivity, high resolving power, fast response time, a low-power consumption that is found to be of giant magnetoresistance effect provides new approaches.
Giant magnetoresistance sensor is to adopt the magnetic Nano metallic multilayer membraneous material with giant magnetoresistance effect to make and integrated circuit compatible electronic devices and components mutually by semiconductor integrated technique.Compare with existing sensors such as Hall element, coil and anisotropic magnetoresistive sensor, giant magnetoresistance sensor has that volume is little, the range of linearity is wide, highly sensitive, low in energy consumption, price is low, temperature stability advantages of higher, has very large advantage and application prospect.
Summary of the invention
The object of this invention is to provide a kind of pit rope on-line measuring device and method based on giant magnetoresistance sensor array, low and be difficult to realize the problems such as the online detection of damage to solve the sensitivity of pick-up unit.
Technical scheme: the invention discloses a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, described device comprises probe, signal condition module, data collecting card, computing machine and locating module, described probe is connected with the input end of signal condition module, the output terminal of signal condition module is connected with computing machine through data collecting card, and locating module end is connected with data collecting card.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, is characterized in that, probe is comprised of excitation unit and magnetic field detection unit.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, it is characterized in that, described excitation unit is comprised of rare-earth permanent magnet, ingot iron and guide rail, and this excitation unit contacts with wire rope, along wire rope axial direction magnetization wire rope.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, it is characterized in that, guide material is igelite, and guide rail diameter just in time wraps wire rope, guide rail is replaceable part, need to change at any time according to the degree of wear of wire rope model or guide rail.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, is characterized in that, described magnetic field detection unit is comprised of 8 giant magnetoresistance sensors along evenly distributed on wire rope circumferencial direction.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, it is characterized in that, described giant magnetoresistance sensor model is SS501A, the 1st connect+5V of the pin power supply of SS501A, the 3rd pin ground connection of SS501A, the 2nd pin and the 4th pin of SS501A are output voltage signal.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, it is characterized in that, described signal condition module by 8 independently signal condition passage form, signal input channel 1 is connected with signal output road 1 through signal condition passage 1, signal input channel 2 is connected with signal output channels 2 through signal condition passage 2, signal input channel 3 is connected with signal output channels 3 through signal condition passage 3, signal input channel 4 is connected with signal output channels 4 through signal condition passage 4, signal input channel 5 is connected with signal output channels 5 through signal condition passage 5, signal input channel 6 is connected with signal output channels 6 through signal condition passage 6, signal input channel 7 is connected with signal output channels 7 through signal condition passage 7, signal input channel 8 is connected with signal output channels 8 through signal condition passage 8, and signal condition passage 1, signal condition passage 2, signal condition passage 3, signal condition passage 4, signal condition passage 5, signal condition passage 6, the circuit of signal condition passage 7 and signal condition passage 8 is identical.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, is characterized in that, described signal condition passage 1 consists of amplifier AD620 and active second-order low-pass filter.The 1st pin of AD620 is connected with AD620 the 8th pin by the first resistance (R1), the 2nd pin that the 2nd pin of AD620 meets SS501A is connected, the 4th pin that the 3rd pin of AD620 meets SS501A is connected, the 4th pin of AD620 and the 5th pin ground connection, the 6th pin of AD620 is by the second resistance (R2), the 3rd resistance (R3) connects the 1st pin of operational amplifier U3, the 7th connect+12V of the pin power supply of AD620, the second resistance (R2) the 2nd pin is by the first electric capacity (C1) ground connection, the 3rd resistance (R3) the 2nd pin is by the second electric capacity (C2) ground connection, the 2nd pin of operational amplifier U3 connects the 4th pin of operational amplifier U3 by the 4th resistance (R4), the 3rd connect+12V of the pin power supply of operational amplifier U3, the 5th pin ground connection of operational amplifier U3.
Described a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array, it is characterized in that, described locating module is comprised of positioning roller and honeywell switch sensor, and four permanent magnets of positioning roller band form and circumferentially evenly distributed along roller of four permanent magnets.
Described a kind of pit rope online test method based on giant magnetoresistance sensor array, it is characterized in that, after excitation unit in probe magnetizes wire rope, the leakage field that the magnetic field detection unit inspection damage of steel cable place consisting of huge magnetoelectricity magnetic resistance sensor produces.Probe output after signal condition resume module and the output signal of locating module are respectively via data collecting card input computing machine.Computing machine carries out denoising to the probe signal collecting, and probe signal and predetermined threshold value after processing are contrasted to determine whether wire rope to be checked exists damage.If the probe signal after processing higher than predetermined threshold value, shows that wire rope to be checked exists damage, further clear and definite type of impairment and size, then determine damage position according to the locating module signal collecting.
Beneficial effect: the probe of apparatus of the present invention is by adopting Novel magnetic field detecting sensor---giant magnetoresistance sensor, can improve sensitivity, antijamming capability and the temperature stability of device, make testing result more accurate, and can determine exactly online and type of impairment and size there is good result of use.
accompanying drawing explanation
Fig. 1 is the theory diagram of pit rope on-line measuring device
Fig. 2 is the sonde configuration schematic diagram of pit rope on-line measuring device
Fig. 3 is the magnetic field detection cellular construction schematic diagram of probe
Fig. 4 is giant magnetoresistance sensor SS501A elementary diagram
Fig. 5 is the theory diagram of signal condition module
Fig. 6 is the circuit theory diagrams of signal condition passage 1
Fig. 7 is the structural representation of locating module
Fig. 8 is probe signal software processing flow chart
In figure, 1, guide rail; 2, rare-earth permanent magnet; 3, ingot iron; 4, magnetic field detection unit; 5, locating module; 6, wire rope roller; 7, giant magnetoresistance sensor; 8, circuit board; 9, positioning roller; 10, permanent magnet; 11, honeywell switch sensor.
Embodiment
Below in conjunction with accompanying drawing, the present invention is described further: the probe of apparatus of the present invention has adopted the giant magnetoresistance sensor of high sensitivity, high resolving power, high-temperature stability, thereby significantly improved the sensitivity of pick-up unit, and this device can accurately judge in wire rope, whether there is damage according to probe signal.If there is damage, this dress also can be determined type of impairment and size.
As shown in Figure 1, this pit rope on-line measuring device comprises probe, signal condition module, data collecting card, computing machine, several parts of locating module.Probe is connected with signal condition module, data collecting card, computing machine, and locating module is connected with data collecting card.
Excitation unit is by after wire rope magnetization, and probe detects the leakage field signal that damage of steel cable place produces, and this signal is together processed via data collecting card input computing machine with the output signal of locating module after signal condition resume module.
The structural representation of probe as shown in Figure 2, is formed by the mutual interlock of identical two parts, and two-part structure is identical.Probe forms by excitation unit and with magnetic field detection unit.
Because passive excitation unit has, volume is little, lightweight, advantages of simple structure and simple, and excitation intensity can meet the requirement of this device to excitation intensity completely, this excitation unit adopts the method for passive excitation, utilize permanent magnet, soft magnetic material and wire rope to form energized circuit, wire rope is carried out to excitation.
Excitation unit is comprised of rare-earth permanent magnet, ingot iron and guide rail.This excitation unit contacts with wire rope, along wire rope axial direction magnetization wire rope.
Guide material is igelite, when probe two parts interlock time, guide rail just in time wraps wire rope, and guide rail need to be changed at any time with the degree of wear of wire rope specification size or guide rail.
Fig. 3 is the structural representation of magnetic field detection unit, and this unit is comprised of the identical giant magnetoresistance sensor of 8 along evenly distributed on wire rope circumferencial direction.In two parts of probe, each part is respectively placed 4 giant magnetoresistance sensors, is fixed on the guide rail of excitation unit.When probe two parts interlock time, 8 giant magnetoresistance sensors are evenly distributed along wire rope circumferencial direction.It is noted that the number of giant magnetoresistance sensor must equal the number of share of stock of wire rope to be detected, so can effectively reduce burst interference of ripple field signal to detection signal of wire rope.If the number of share of stock of wire rope to be checked is not 8, needing increases or reduces the magnetic field sensor number in magnetic field detection unit, makes it consistent with the number of share of stock of wire rope to be checked.
Compare with traditional Magnetic Sensors such as Hall element and anisotropic magnetoresistive sensor, giant magnetoresistance sensor has that volume is little, the range of linearity is wide, highly sensitive, low in energy consumption, price is low, temperature stability advantages of higher, so the magnetic field detection unit of this device adopts giant magnetoresistance sensor.
The giant magnetoresistance sensor model of magnetic field detection unit is SS501A, and the connection principle of SS501A as shown in Figure 4.The 1st connect+5V of the pin power supply of SS501A, the 3rd pin ground connection of SS501A, the 3rd pin and the 4th pin of SS501A are output voltage signal.
Fig. 5 is the theory diagram of signal condition passage, signal condition module by 8 independently signal condition passage form, signal input channel 1 is connected with signal output road 1 through signal condition passage 1, signal input channel 2 is connected with signal output channels 2 through signal condition passage 2, signal input channel 3 is connected with signal output channels 3 through signal condition passage 3, signal input channel 4 is connected with signal output channels 4 through signal condition passage 4, signal input channel 5 is connected with signal output channels 5 through signal condition passage 5, signal input channel 6 is connected with signal output channels 6 through signal condition passage 6, signal input channel 7 is connected with signal output channels 7 through signal condition passage 7, signal input channel 8 is connected with signal output channels 8 through signal condition passage 8.
The giant magnetoresistance sensor number that signal condition number of channels need to equal to pop one's head in and contain in internal magnetic field magnetic field detection unit.The circuit of 8 signal condition passages is identical, and the circuit of signal condition passage 1, signal condition passage 2, signal condition passage 3, signal condition passage 4, signal condition passage 5, signal condition passage 6, signal condition passage 7 and signal condition passage 8 is identical.。
Fig. 6 is the circuit theory diagrams of signal condition passage 1.Signal condition passage 1 consists of amplifier AD620 and second order active low-pass filter.Because giant magnetoresistance sensor chip is output as a pair of difference low-frequency voltage signal, the wave filter adopting is low-pass filter, and the filtering performance of active filter circuit, than passive filter circuit superior performance, therefore adopts active second-order low-pass filter circuit in low-frequency range.
The 1st pin of AD620 is connected with AD620 the 8th pin by the first resistance (R1), the 2nd pin of AD620 connects the 4th pin of SS501A, the 3rd pin of AD620 connects the 2nd pin of SS501A, the 4th pin ground connection of AD620, the 5th pin ground connection of AD620, the 6th pin of AD620 is by the second resistance (R2), the 3rd resistance (R3) connects operational amplifier (U1) the 1st pin, the 7th pin of AD620 connects positive 12V power supply, the second resistance (R2) the 2nd pin is by the first electric capacity (C1) ground connection, the 3rd resistance (R3) the 2nd pin is by the second electric capacity (C2) ground connection, the 2nd pin of operational amplifier (U1) connects the 4th pin of operational amplifier (U1) by the 4th resistance (R4), the 3rd pin of operational amplifier (U1) connects positive 12V power supply, the 5th pin ground connection of operational amplifier (U1).
Because data acquisition calorie requirement is by the output signal input computing machine of the output signal of probe and locating module, so capture card number of channels need to be greater than probe output quantity and locating module output signal quantity sum, situation about increasing in order to meet probe output quantity that the conversion of wire rope model causes in addition, this device employing 16 channel data capture cards.
Fig. 7 is locating module structural representation, and it is comprised of positioning roller and honeywell switch sensor.Four permanent magnets of positioning roller band, and circumferentially evenly distributed along positioning roller of four permanent magnets.
Positioning roller is coaxially connected with wire rope roller, and wire rope roller and wire rope compress, and is driven the passive rotation of doing fricton-tight friction by wire rope.Positioning roller rotates with wire rope roller, and whenever a permanent magnet is during near honeywell switch sensor, honeywell switch sensor can produce a pulse signal, and positioning roller often turns around, and produces four pulse signals.
Wire rope apart from computing formula is: distance=number of pulses * positioning roller girth/4.
Fig. 8 is probe signal software processing flow chart, and the output signal of probe is inputted after computing machine via data collecting card, utilizes computer software to analyze detection signal.First detection signal is carried out to denoising, detection signal is carried out to wavelet decomposition, the main information that the low frequency signal after decomposition has comprised damage signal, so need be by high-frequency signal filtering.So repeatedly, can effectively improve signal to noise ratio (S/N ratio).
Manufacturing artificial damage on some wire rope samples, the device proposing by the present invention detects the leakage field signal of artificial damage, by wavelet analysis, the detection signal of artificial damage is carried out after feature extraction, utilize the artificial damage test data of obtaining to set up and optimize radial basis neural network and the parameter of damage of steel cable.When the wire rope probe signal to be checked after denoising is greater than predetermined threshold value, computer software, the radial basis neural network after the probe signal input after processing is optimized, can determine in wire rope to be checked, whether there is damage.If there is damage in wire rope to be checked, radial basis neural network after optimizing can be identified the type of impairment in wire rope to be checked, and the geometric parameter that can quantitatively determine damage is lesion size, finally record the information such as type of impairment, lesion size and damage position, thereby reach the online object detecting of pit rope damage.
Claims (10)
1. the pit rope on-line measuring device based on giant magnetoresistance sensor array, comprise probe, signal condition module, data collecting card, computing machine, locating module, it is characterized in that probe is connected with the input end of signal condition module, the output terminal of signal condition module is connected with computing machine through data collecting card, locating module end is connected with data collecting card.
2. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 1, is characterized in that, probe is comprised of excitation unit and magnetic field detection unit.
3. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 2, it is characterized in that, described excitation unit is comprised of rare-earth permanent magnet, ingot iron and guide rail, this excitation unit contacts with wire rope, along wire rope axial direction magnetization wire rope.
4. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 3, it is characterized in that, guide material is igelite, guide rail diameter just in time wraps wire rope, guide rail is replaceable part, need to change at any time according to the degree of wear of wire rope model or guide rail.
5. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 2, is characterized in that, described magnetic field detection unit is comprised of 8 giant magnetoresistance sensors along evenly distributed on wire rope circumferencial direction.
6. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 5, it is characterized in that described giant magnetoresistance sensor model is SS501A, the 1st connect+5V of the pin power supply of SS501A, the 3rd pin ground connection of SS501A, the 2nd pin and the 4th pin of SS501A are output voltage signal.
7. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 1, it is characterized in that, described signal condition module by 8 independently signal condition passage form, wherein signal input channel 1 is connected with signal output road 1 through signal condition passage 1, signal input channel 2 is connected with signal output channels 2 through signal condition passage 2, signal input channel 3 is connected with signal output channels 3 through signal condition passage 3, signal input channel 4 is connected with signal output channels 4 through signal condition passage 4, signal input channel 5 is connected with signal output channels 5 through signal condition passage 5, signal input channel 6 is connected with signal output channels 6 through signal condition passage 6, signal input channel 7 is connected with signal output channels 7 through signal condition passage 7, signal input channel 8 is connected with signal output channels 8 through signal condition passage 8, and signal condition passage 1, signal condition passage 2, signal condition passage 3, signal condition passage 4, signal condition passage 5, signal condition passage 6, the circuit of signal condition passage 7 and signal condition passage 8 is identical.
8. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 7, it is characterized in that, described signal condition passage 1 consists of amplifier AD620 and active second-order low-pass filter, the 1st pin of AD620 is connected with AD620 the 8th pin by the first resistance (R1), the 2nd pin that the 2nd pin of AD620 meets SS501A is connected, the 4th pin that the 3rd pin of AD620 meets SS501A is connected, the 4th pin of AD620 and the 5th pin ground connection, the 6th pin of AD620 is by the second resistance (R2), the 3rd resistance (R3) connects the 1st pin of operational amplifier U3, the 7th connect+12V of the pin power supply of AD620, the second resistance (R2) the 2nd pin is by the first electric capacity (C1) ground connection, the 3rd resistance (R3) the 2nd pin is by the second electric capacity (C2) ground connection, the 2nd pin of operational amplifier U3 connects the 4th pin of operational amplifier U3 by the 4th resistance (R4), the 3rd connect+12V of the pin power supply of operational amplifier U3, the 5th pin ground connection of operational amplifier U3.
9. a kind of pit rope on-line measuring device based on giant magnetoresistance sensor array according to claim 1, it is characterized in that, described locating module is comprised of positioning roller and honeywell switch sensor, and positioning roller is comprised of four permanent magnets and circumferentially evenly distributed along roller of four permanent magnets.
10. the pit rope online test method based on giant magnetoresistance sensor array, it is characterized in that, excitation unit in probe is by after wire rope magnetization, the leakage field that the magnetic field detection unit inspection damage of steel cable place consisting of huge magnetoelectricity magnetic resistance sensor produces, probe output after signal condition resume module and the output signal of locating module are respectively via data collecting card input computing machine, computing machine carries out denoising to the probe signal collecting, and probe signal and predetermined threshold value after processing are contrasted to determine whether wire rope to be checked exists damage, if the probe signal after processing is higher than predetermined threshold value, show that wire rope to be checked exists damage, further clear and definite type of impairment and size, according to the locating module signal collecting, determine damage position again.
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