CN104280452A - Wire rope defect scanning system based on circular array weak magnetic detection sensor - Google Patents
Wire rope defect scanning system based on circular array weak magnetic detection sensor Download PDFInfo
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Abstract
一种基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统，属于无损检测技术领域。其包括直线导轨式扫描机构、圆周阵列式弱磁检测传感器、钢索夹持组件、运动控制单元和数据采集单元。直线导轨式扫描机构可搭载圆周阵列式弱磁检测传感器，以可控速度相对钢索做匀速直线运动。本发明所提出的圆周阵列式弱磁检测传感器采用亥姆霍兹线圈与沿钢索圆周均布的高灵敏度隧道磁阻元件，其直流励磁功耗低，对钢索不产生吸附力作用；采用焊接隧道磁阻元件的柔性印制电路板，其体积小，易弯折，可实现断丝、磨损的轴向与周向定位。直线导轨式扫描机构与钢索夹持组件可确保检测过程中，弱磁检测传感器与钢索间的提离距离保持一致。
The invention relates to a steel cable defect scanning system based on a circular array weak magnetic detection sensor, which belongs to the technical field of nondestructive testing. It includes a linear guide rail type scanning mechanism, a circular array type weak magnetic detection sensor, a steel cable clamping component, a motion control unit and a data acquisition unit. The linear guide rail type scanning mechanism can be equipped with a circular array type weak magnetic detection sensor, and it can make a uniform linear motion relative to the steel cable at a controllable speed. The circular array type magnetic field weakening detection sensor proposed by the present invention adopts Helmholtz coils and high-sensitivity tunnel magneto-resistive elements uniformly distributed along the circumference of the steel cable, and its DC excitation power consumption is low, and no adsorption force is produced on the steel cable; The flexible printed circuit board welded with the tunnel magnetoresistive element is small in size and easy to bend, and can realize the axial and circumferential positioning of broken wires and wear. The linear guide rail type scanning mechanism and the steel cable clamping assembly can ensure that the lift-off distance between the weak magnetic detection sensor and the steel cable is consistent during the detection process.
Description
技术领域technical field
本发明属于无损检测技术领域，特别针对钢索的无损检测，是一种基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统。The invention belongs to the technical field of nondestructive testing, and is particularly aimed at the nondestructive testing of steel cables, and is a steel cable defect scanning system based on a circular array type weak magnetic detection sensor.
背景技术Background technique
钢索一般由多根高强度钢丝拧绕成股，再由数条绳股绕索芯绕制而成。其具有高抗拉、低抗弯和低抗剪等优点，广泛应用于煤炭、冶金、建筑、旅游等国民经济各主要行业和部门。钢索在使用过程中由于种种原因，常出现各类缺陷，包括钢索材料横截面损失(LMA)和局部缺陷(LF)。钢索的这些损伤引发的事故将危机人身和设备安全。因此，发展钢索缺陷无损检测技术，准确获取缺陷信息，进行钢索安全性评估并及时提出补救方案，以保证钢索使用安全，提高钢索使用寿命，具有重要的社会和经济价值。Steel cables are usually twisted into strands by multiple high-strength steel wires, and then wound by several strands around the cable core. It has the advantages of high tensile strength, low bending resistance and low shear resistance, and is widely used in various major industries and departments of the national economy such as coal, metallurgy, construction, and tourism. Due to various reasons during the use of steel cables, various defects often appear, including the cross-sectional loss (LMA) and local defects (LF) of the steel cable material. Accidents caused by these damages of steel cables will endanger personal and equipment safety. Therefore, it is of great social and economic value to develop non-destructive detection technology for steel cable defects, accurately obtain defect information, evaluate the safety of steel cables and propose remedial solutions in time to ensure the safety of steel cables and improve the service life of steel cables.
自1906年世界上第一台钢丝绳探伤仪面世至今,已发展出多种钢丝绳无损检测方法，主要包括超声波法、电涡流法和漏磁法等。超声波在复杂钢索中衰减严重且其在钢索中传播特性较为复杂，对缺陷信号的提取较为困难；电涡流法受趋肤效应限制，检测深度有限，一般只能检测钢索表层缺陷。相比而言，漏磁法是较为成熟的钢索缺陷检测技术，具有检测空间分辨率高、响应时间快，可在线检测等优点。Since the world's first wire rope flaw detector came out in 1906, a variety of wire rope non-destructive testing methods have been developed, mainly including ultrasonic method, eddy current method and magnetic flux leakage method. The attenuation of ultrasonic waves in complex steel cables is serious and its propagation characteristics in steel cables are relatively complicated, so it is difficult to extract defect signals; the eddy current method is limited by the skin effect, and the detection depth is limited, and generally it can only detect surface defects of steel cables. In contrast, the magnetic flux leakage method is a relatively mature wire rope defect detection technology, which has the advantages of high detection space resolution, fast response time, and online detection.
钢索漏磁检测的励磁方式分为无源励磁和有源励磁。无源励磁多采用强磁力的汝铁硼永磁体作为励磁源，并采用笨重的轭铁作为导磁体。永磁铁强大的吸附力和传感器庞大笨重的外形，使得传感器与钢索难以顺利地相对匀速运动，并且难以保证传感器与钢索提离距离的一致性。传统的有源励磁方法需采用稳压电源向励磁线圈中通入较大电流，线圈发热效应严重，不便于实际应用。The excitation methods of cable magnetic flux leakage detection are divided into passive excitation and active excitation. Passive excitation mostly uses strong magnetic force Ru-Fe-B permanent magnets as the excitation source, and uses bulky yoke iron as the magnetizer. The strong adsorption force of the permanent magnet and the bulky and bulky shape of the sensor make it difficult for the sensor and the cable to move at a relatively constant speed smoothly, and it is difficult to ensure the consistency of the distance between the sensor and the cable. The traditional active excitation method needs to use a regulated power supply to pass a large current into the excitation coil, and the heating effect of the coil is serious, which is not convenient for practical application.
钢索缺陷检测的过程中，传感器与待测钢索的提离距离应保持一致，传统的保持两者提离距离一致的方法是通过安装导轮或滑靴，该方法会造成导轮或滑靴的磨损。中国专利CN202994584U《一种简易钢索拉伸装置》提出的钢索拉伸方法可用于设计预紧钢索的装置，在此基础上设计完全非接触和恒定提离距离的钢索缺陷扫查系统。In the process of cable defect detection, the lift-off distance between the sensor and the steel cable to be tested should be consistent. The traditional method of keeping the two lift-off distances consistent is to install guide wheels or sliding shoes, which will cause guide wheels or slippery Boot wear. The cable stretching method proposed in Chinese patent CN202994584U "A Simple Steel Cable Tensioning Device" can be used to design a pre-tensioned steel cable device, and on this basis, a completely non-contact and constant lift-off distance steel cable defect scanning system is designed .
发明内容Contents of the invention
本发明的目的在于提供一种在实验室条件下模拟现场检测的基于圆周阵列式弱磁检测传感器的弱磁场、低功耗的钢索缺陷扫查系统。系统不仅具有高分辨力和高灵敏度，而且能够避免无源检测的强磁吸附力和传统有源检测发热与供电设备庞大的弱点，能够实现钢索与传感器间的匀速相对运动，确保两者提离距离的一致性。The purpose of the present invention is to provide a weak magnetic field and low power consumption steel cable defect scanning system based on a circular array type weak magnetic detection sensor that simulates on-site detection under laboratory conditions. The system not only has high resolution and high sensitivity, but also can avoid the strong magnetic adsorption force of passive detection and the huge weakness of traditional active detection heating and power supply equipment, and can realize the uniform relative motion between the cable and the sensor, ensuring that both Consistency of distance.
本发明提出基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统，它包括：直线导轨式扫描机构、圆周阵列式弱磁检测传感器、钢索夹持组件、运动控制单元和数据采集单元。The invention proposes a steel cable defect scanning system based on a circular array type weak magnetic detection sensor, which includes: a linear guide rail type scanning mechanism, a circular array type weak magnetic detection sensor, a steel cable clamping assembly, a motion control unit and a data acquisition unit.
所述直线导轨式扫描机构用于调节系统水平和搭载圆周阵列式弱磁检测传感器并使其与钢索发生相对运动；The linear guide rail type scanning mechanism is used to adjust the system level and carry a circular array type weak magnetic detection sensor and make it move relative to the steel cable;
所述圆周阵列式弱磁检测传感器安装在直线导轨式扫描机构上，用于沿轴向均匀磁化被测钢索、屏蔽环境磁场和检测钢索缺陷信号；The circular array type magnetic field weakening detection sensor is installed on the linear guide rail type scanning mechanism, and is used for uniformly magnetizing the steel cable under test along the axial direction, shielding the environmental magnetic field and detecting the defect signal of the steel cable;
所述钢索夹持组件用于预紧和固定钢索；The steel cable clamping assembly is used for pre-tightening and fixing the steel cable;
所述运动控制单元和数据采集单元通过运动控制卡和数据采集卡分别与直线导轨式扫描机构和圆周阵列式弱磁检测传感器通信，用于控制导轨的运动和处理传感器采集的缺陷信号。The motion control unit and the data acquisition unit communicate with the linear guide rail scanning mechanism and the circular array magnetic field weakening detection sensor respectively through the motion control card and the data acquisition card, and are used to control the motion of the guide rail and process the defect signals collected by the sensors.
特别地，所述直线导轨式扫描机构包括水平调整底座、XY两轴运动导轨和钢索固定装置安装梁。In particular, the linear guide rail type scanning mechanism includes a horizontal adjustment base, an XY two-axis motion guide rail and a steel cable fixing device installation beam.
所述水平调整底座由角座和铝型材组装而成。其中有四个竖直放置的铝型材分别固定于四个可调水平的角座上，两对铝型材通过角接件固定于四个竖直放置的铝型材中部，顶部结构同上。水平调整底座用于调节系统水平。The horizontal adjustment base is assembled from a corner seat and an aluminum profile. Among them, four vertically placed aluminum profiles are respectively fixed on four adjustable horizontal corner seats, and two pairs of aluminum profiles are fixed in the middle of the four vertically placed aluminum profiles through corner joints, and the top structure is the same as above. The leveling base is used to adjust the system level.
所述XY两轴运动导轨由“工”字形装配的三根导轨和两个电机组成。其中两根平行导轨构成X运动轴，与之垂直的导轨构成Y运动轴。X轴的平行导轨固定在水平调整底座顶部两根铝型材上，Y轴导轨固定在X轴导轨的两个滑台上。两个电机分别与两轴导轨的一端相连，其中X轴导轨通过传动轴实现同步运动。两轴运动导轨用于搭载圆周阵列式弱磁检测传感器并实现传感器与钢索的相对运动。The XY two-axis motion guide rail is composed of three guide rails assembled in the shape of "I" and two motors. Two of the parallel guide rails constitute the X motion axis, and the vertical guide rails constitute the Y motion axis. The parallel guide rails of the X-axis are fixed on two aluminum profiles on the top of the horizontal adjustment base, and the Y-axis guide rails are fixed on the two sliding tables of the X-axis guide rails. The two motors are respectively connected to one end of the two-axis guide rail, wherein the X-axis guide rail realizes synchronous movement through the transmission shaft. The two-axis motion guide rail is used to carry the circular array type weak magnetic detection sensor and realize the relative movement between the sensor and the steel cable.
所述钢索固定装置安装梁平行X轴导轨，固定安装在水平调整底座顶部，用于安装钢索固定装置。The installation beam of the cable fixing device is parallel to the X-axis guide rail, and is fixedly installed on the top of the horizontal adjustment base for installing the cable fixing device.
特别地，所述圆周阵列式弱磁检测传感器包括：传感器夹持装置、亥姆霍兹线圈、隧道磁阻探头、分体式磁屏蔽壳、印制电路板。In particular, the circular array type magnetic field weakening detection sensor includes: a sensor clamping device, a Helmholtz coil, a tunnel reluctance probe, a split magnetic shielding shell, and a printed circuit board.
所述传感器夹持装置由底座和传感器夹具组成。所述底座固定于Y轴导轨滑台上，它的中部开有飞翼形凹槽，其中两翼凹槽用于固定励磁结构，中部凹槽用于固定传感器夹具。所述传感器夹具分上、下两部分，其中下半部分为开有半圆槽的长方体，其底部固定于底座中部的凹槽中，上半部分为带双耳的半圆形结构，其双耳结构与下半部分通过螺栓固定。传感器夹持装置用于夹持分体式磁屏蔽壳和固定亥姆霍兹线圈。The sensor clamping device is composed of a base and a sensor clamp. The base is fixed on the Y-axis guide rail slide table, and its middle part has a flying wing-shaped groove, wherein the two wing grooves are used to fix the excitation structure, and the middle groove is used to fix the sensor fixture. The sensor fixture is divided into upper and lower parts, wherein the lower half is a cuboid with a semicircular groove, the bottom of which is fixed in the groove in the middle of the base, and the upper half is a semicircular structure with two ears. The structure is fixed to the lower half by bolts. The sensor clamping device is used to clamp the split magnetic shielding shell and fix the Helmholtz coil.
所述分体式磁屏蔽壳为两个对称的壳体结构，其横截面呈环形，两端有环形端盖。分体式磁屏蔽壳用于屏蔽环境磁场，在屏蔽腔体内部构造近零磁场空间。The split-type magnetic shielding shell has two symmetrical shell structures, the cross section of which is ring-shaped, with ring-shaped end caps at both ends. The split-type magnetic shielding shell is used to shield the ambient magnetic field, and a near-zero magnetic field space is constructed inside the shielding cavity.
所述亥姆霍兹线圈由两个环形线圈和锂电池组成。两个环形线圈分别套在屏蔽结构两端并固定于底座的两翼凹槽中，两者串联且电流方向一致。亥姆霍兹线圈用于沿轴向磁化从其中心穿过的钢索。The Helmholtz coil consists of two toroidal coils and a lithium battery. The two ring coils are respectively sleeved at both ends of the shielding structure and fixed in the grooves of the two wings of the base, and the two are connected in series with the same current direction. A Helmholtz coil is used to axially magnetize a steel cable passing through its center.
所述隧道磁阻探头由隧道磁阻元件和传感器固定环组成。所述传感器固定环为管状结构，其与分体式磁屏蔽壳内腔过渡配合，其外壁沿周向均匀分布N(2≤N≤16)个凹槽，其内壁均匀分布N个浅槽，浅槽用于胶封保护柔性印制电路板，浅槽与外壁凹槽位置相对应并相互连通用于穿过柔性印制电路板。所述隧道磁阻元件均匀分布并胶封固定于传感器固定环的凹槽内。The tunnel magneto-resistance probe is composed of a tunnel magneto-resistance element and a sensor fixing ring. The sensor fixing ring is a tubular structure, which transitionally fits with the inner cavity of the split-type magnetic shielding shell. N (2≤N≤16) grooves are evenly distributed on the outer wall along the circumference, and N shallow grooves are evenly distributed on the inner wall. The groove is used for sealing and protecting the flexible printed circuit board, and the shallow groove corresponds to the position of the groove on the outer wall and communicates with each other for passing through the flexible printed circuit board. The tunnel magneto-resistance elements are evenly distributed and glued and fixed in the groove of the sensor fixing ring.
所述印制电路板由硬性印制电路板(PCB)和柔性印制电路板(FPC)组成。所述硬性印制电路板安装于传感器夹持装置的底座上，其由3～12V转1V电路和信号转接电路构成，用于为隧道磁阻元件供电和向数据采集卡发送检测信号。所述柔性印制电路板一端焊接隧道磁阻元件，一端连接硬性印制电路板，其用于为隧道磁阻元件传输电能和向硬性印制电路板输出检测信号。The printed circuit board is composed of a rigid printed circuit board (PCB) and a flexible printed circuit board (FPC). The rigid printed circuit board is installed on the base of the sensor clamping device, which is composed of a 3-12V to 1V circuit and a signal transfer circuit, and is used to supply power to the tunnel magnetoresistive element and send detection signals to the data acquisition card. One end of the flexible printed circuit board is welded to the tunnel magneto-resistance element, and the other end is connected to the rigid printed circuit board, which is used for transmitting electric energy for the tunnel magneto-resistive element and outputting detection signals to the rigid printed circuit board.
特别地，所述钢索夹持组件包括：钢索预紧装置和钢索固定装置。In particular, the cable clamping assembly includes: a cable pretensioning device and a cable fixing device.
所述钢索预紧装置由穿心式液压泵、挡板、刚性底座和锚头组成，其用于预紧钢索，拉伸钢索至准直状态。The steel cable pretensioning device is composed of a through-hole hydraulic pump, a baffle, a rigid base and an anchor head, which is used for pretensioning the steel cable and stretching the steel cable to an aligned state.
所述钢索固定装置成对使用，它由底座、支架和固定螺栓组成。底座固定安装在钢索固定装置安装梁上。四个固定螺栓分别从“回”形支架四个方向穿过指向中心。钢索固定装置用于调整钢索空间位置并夹持固定待测钢索。Described cable fixing device is used in pairs, and it is made up of base, support and fixing bolt. The base is fixedly installed on the installation beam of the steel cable fixing device. The four fixing bolts respectively pass through the four directions of the "back" shaped support and point to the center. The steel cable fixing device is used for adjusting the spatial position of the steel cable and clamping and fixing the steel cable to be tested.
所述传感器夹持装置采用有机玻璃材料，所述亥姆霍兹线圈采用漆包铜线材料，所述分体式磁屏蔽壳采用低碳钢材料，所述传感器固定环采用有机玻璃材料。The sensor clamping device is made of plexiglass, the Helmholtz coil is made of enamelled copper wire, the split magnetic shielding shell is made of low carbon steel, and the sensor fixing ring is made of plexiglass.
所述传感器夹持装置、亥姆霍兹线圈、分体式屏蔽壳、传感器固定环和钢索均同轴。The sensor clamping device, the Helmholtz coil, the split shield shell, the sensor fixing ring and the steel cable are all coaxial.
所述传感器固定环的内径比分体式磁屏蔽壳端盖的内径小1mm～2mm，比被测钢索直径大1mm～2mm。其内表面沿周向均匀分布N个深0.5mm～1mm、宽1mm～2mm从传感器支撑一端延伸至其中部的浅槽，浅槽与外壁凹槽位置相对并相互连通。The inner diameter of the sensor fixing ring is 1mm-2mm smaller than the inner diameter of the end cover of the split magnetic shielding shell, and 1mm-2mm larger than the diameter of the steel cable to be tested. N shallow grooves with a depth of 0.5 mm to 1 mm and a width of 1 mm to 2 mm are evenly distributed along the inner surface along the circumference, extending from one end of the sensor support to the middle of the center, and the shallow grooves are opposite to and connected to the grooves on the outer wall.
所述运动控制单元用于控制直线导轨的运动。所述数据采集单元用于接收传感器发送的信号并将处理后信号输出至计算机。所述计算机通过运动控制卡控制导轨匀速运动的速度和通过数据采集卡采集缺陷信号，并通过对钢索缺陷漏磁信号的处理，判断钢索有无缺陷和计算缺陷的位置和大小，完成对钢索的定性检测和定量测量。The motion control unit is used to control the motion of the linear guide rail. The data acquisition unit is used to receive the signal sent by the sensor and output the processed signal to the computer. The computer controls the speed of the uniform motion of the guide rail through the motion control card and collects the defect signal through the data acquisition card, and judges whether there is a defect in the steel cable and calculates the position and size of the defect through the processing of the magnetic flux leakage signal of the cable defect, and completes the inspection. Qualitative detection and quantitative measurement of wire rope.
本发明通过采用上述技术方案，可以获得以下优点和有益效果：本发明通过水平调节底座调节系统的水平，通过钢索夹持组件预紧和固定钢索，很好地保证了钢索与圆周阵列式弱磁检测传感器提离距离的一致和避免了两者的接触磨损。本发明通过运动控制单元和运动导轨有效保证了圆周阵列式弱磁检测传感器与钢索的匀速相对运动。本发明采用隧道磁阻元件和锂电池供电的亥姆霍兹线圈，有效地减弱了圆周阵列式弱磁检测传感器与钢索的吸附力，克服了有源励磁的发热和供电设备庞大的问题。By adopting the above technical scheme, the present invention can obtain the following advantages and beneficial effects: the present invention adjusts the level of the base adjustment system by horizontally adjusting the level of the system, and pre-tightens and fixes the steel cables through the cable clamping components, so that the steel cables and the circumferential array are well guaranteed The consistency of the lifting distance of the type weak magnetic detection sensor and the contact wear of the two are avoided. The invention effectively ensures the uniform relative motion between the circular array type magnetic field weakening detection sensor and the steel cable through the motion control unit and the motion guide rail. The invention adopts the tunnel magnetoresistive element and the Helmholtz coil powered by lithium battery, effectively weakens the adsorption force between the circular array type weak magnetic detection sensor and the steel cable, and overcomes the problems of active excitation heating and huge power supply equipment.
附图说明Description of drawings
图1为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统结构图；Fig. 1 is a structural diagram of a steel cable defect scanning system based on a circular array type weak magnetic detection sensor provided by an embodiment of the present invention;
图2为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统装配示意图；Fig. 2 is a schematic diagram of assembly of a steel cable defect scanning system based on a circular array type weak magnetic detection sensor provided by an embodiment of the present invention;
图3为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器示意图；Fig. 3 is a schematic diagram of a circular array type magnetic field weakening detection sensor based on a steel cable defect scanning system provided by an embodiment of the present invention;
图4为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器径向剖视图；Fig. 4 is a radial cross-sectional view of the circumferential array type magnetic field weakening detection sensor of the steel cable defect scanning system based on the circumferential array type magnetic field weakening detection sensor provided by the embodiment of the present invention;
图5为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器轴向剖视图；Fig. 5 is an axial sectional view of the circumferential array type magnetic field weakening detection sensor of the steel cable defect scanning system based on the circumferential array type magnetic field weakening detection sensor provided by the embodiment of the present invention;
图6为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统钢索固定装置示意图；Fig. 6 is a schematic diagram of a steel cable fixing device for a steel cable defect scanning system based on a circumferential array type weak magnetic detection sensor provided by an embodiment of the present invention;
图7为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统同轴装配示意图。Fig. 7 is a schematic diagram of the coaxial assembly of the wire rope defect scanning system based on the circumferential array weak magnetic detection sensor provided by the embodiment of the present invention.
图中：In the picture:
1、直线导轨式扫描机构，2、圆周阵列式弱磁检测传感器，3、钢索夹持组件，4、运动控制单元，5、数据采集单元，6、水平调整底座，6-1、角座，6-2、铝型材，7、XY两轴运动导轨，7-1、X轴导轨，7-2、Y轴导轨，7-3、电机，8、钢索固定装置安装梁，9、钢索固定装置，9-1固定底座，9-2、支架，9-3、固定螺栓，10、钢索预紧装置，10-1、穿心式液压泵，10-2、挡板，10-3、刚性底座，10-4、锚头，11、传感器夹持装置，11-1底座，11-2、传感器夹具，12、分体式磁屏蔽壳，13、亥姆霍兹线圈，14、隧道磁阻探头，14-1隧道磁阻元件，14-2、传感器固定环，15、印制电路板，15-1、硬性印制电路板PCB，15-2、柔性印制电路板FPC，16、钢索。1. Linear guide rail type scanning mechanism, 2. Circumferential array type weak magnetic detection sensor, 3. Cable clamping component, 4. Motion control unit, 5. Data acquisition unit, 6. Horizontal adjustment base, 6-1, Angle seat , 6-2, aluminum profiles, 7, XY two-axis motion guide rail, 7-1, X-axis guide rail, 7-2, Y-axis guide rail, 7-3, motor, 8, steel cable fixing device installation beam, 9, steel Cable fixing device, 9-1 fixed base, 9-2, bracket, 9-3, fixing bolt, 10, steel cable pretensioning device, 10-1, through-heart hydraulic pump, 10-2, baffle plate, 10- 3. Rigid base, 10-4, anchor head, 11, sensor clamping device, 11-1 base, 11-2, sensor fixture, 12, split magnetic shielding shell, 13, Helmholtz coil, 14, tunnel Magnetic resistance probe, 14-1 Tunnel magnetic resistance element, 14-2, sensor fixing ring, 15, printed circuit board, 15-1, rigid printed circuit board PCB, 15-2, flexible printed circuit board FPC, 16 , Cable.
具体实施方式Detailed ways
本发明通过安装在水平调整底座上的运动导轨搭载圆周阵列式弱磁检测传感器沿预紧固定的钢索进行缺陷扫查。本发明能够有效保证传感器与钢索间的提离距离，以及两者间的相对运动，极大减小传感器对钢索的吸附力，缩减传感器重量，屏蔽环境磁场干扰，提高钢索磁化的均匀性，以及对缺陷的检测定位和定量精度。In the invention, the moving guide rail installed on the horizontal adjustment base is equipped with a circular array type weak magnetic detection sensor to scan for defects along a pre-tightened fixed steel cable. The present invention can effectively ensure the lifting distance between the sensor and the steel cable, as well as the relative movement between the two, greatly reduce the adsorption force of the sensor on the steel cable, reduce the weight of the sensor, shield the interference of the environmental magnetic field, and improve the uniformity of the magnetization of the steel cable performance, as well as the detection, positioning and quantitative accuracy of defects.
下面结合附图对本发明的具体实施方式作进一步说明。在此需要说明的是，实施方式的说明用以帮助理解本发明，并不构成对本发明的限定。The specific embodiments of the present invention will be further described below in conjunction with the accompanying drawings. It should be noted here that the descriptions of the embodiments are used to help understanding of the present invention, and are not intended to limit the present invention.
图1为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统结构示意图。Fig. 1 is a schematic structural diagram of a wire rope defect scanning system based on a circular array type magnetic field weakening detection sensor provided by an embodiment of the present invention.
本实施例中基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统包括：直线导轨式扫描机构1、圆周阵列式弱磁检测传感器2、钢索夹持组件3、运动控制单元4和数据采集单元5。所述直线导轨式扫描机构1包括：水平调整底座6、XY两轴运动导轨7和钢索固定装置安装梁8；所述圆周阵列式弱磁检测传感器2包括：传感器夹持装置11、分体式磁屏蔽壳12、亥姆霍兹线圈13、隧道磁阻探头14和印制电路板15；所述钢索夹持组件3包括钢索固定装置9和钢索预紧装置10。In this embodiment, the wire rope defect scanning system based on the circular array type magnetic field weakening detection sensor includes: a linear guide rail type scanning mechanism 1, a circular array type magnetic field weakening detection sensor 2, a steel cable clamping assembly 3, a motion control unit 4 and data Acquisition unit 5. The linear guide rail type scanning mechanism 1 includes: a horizontal adjustment base 6, an XY two-axis motion guide rail 7 and a steel cable fixing device installation beam 8; the circular array type magnetic field weakening detection sensor 2 includes: a sensor clamping device 11, a split type Magnetic shielding shell 12 , Helmholtz coil 13 , tunnel magnetoresistance probe 14 and printed circuit board 15 ; the cable clamping assembly 3 includes cable fixing device 9 and cable pretensioning device 10 .
所述水平调整底座6用于固定XY两轴运动导轨7和钢索固定装置安装梁8；所述XY两轴运动导轨7用于固定圆周阵列式弱磁检测传感器2；所述钢索固定装置安装梁8用于安装固定钢索固定装置9；所述传感器夹持装置11用于固定分体式磁屏蔽壳12和亥姆霍兹线圈13；所述亥姆霍兹线圈13用于沿轴向均匀磁化待测钢索16；所述分体式磁屏蔽壳12用于屏蔽环境磁场并固定隧道磁阻探头14；隧道磁阻探头14用于检测钢索16缺陷；所述数据采集单元5用于接收处理隧道磁阻探头14的检测信号；所述运动控制单元4用于控制XY两轴运动导轨7的运动。The horizontal adjustment base 6 is used to fix the XY two-axis motion guide rail 7 and the installation beam 8 of the cable fixing device; the XY two-axis motion guide rail 7 is used to fix the circular array type weak magnetic detection sensor 2; the steel cable fixing device The installation beam 8 is used to install and fix the cable fixing device 9; the sensor clamping device 11 is used to fix the split type magnetic shielding shell 12 and the Helmholtz coil 13; the Helmholtz coil 13 is used for axially Uniformly magnetize the steel cable 16 to be tested; the split magnetic shielding shell 12 is used to shield the environmental magnetic field and fix the tunnel reluctance probe 14; the tunnel reluctance probe 14 is used to detect the defect of the steel cable 16; the data acquisition unit 5 is used to The detection signal of the tunnel magnetoresistance probe 14 is received and processed; the motion control unit 4 is used to control the movement of the XY two-axis motion guide rail 7 .
图2为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统装配示意图；Fig. 2 is a schematic diagram of assembly of a steel cable defect scanning system based on a circular array type weak magnetic detection sensor provided by an embodiment of the present invention;
所述水平调整底座6由角座6-1和铝型材6-2组装而成，其中四个竖直放置的铝型材6-2分别固定于四个可调水平的角座6-1上，两对铝型材6-2通过角接件固定于四个竖直放置的铝型材6-2中部，顶部四根铝型材6-2安装方式同上。The horizontal adjustment base 6 is assembled from a corner seat 6-1 and an aluminum profile 6-2, wherein four vertically placed aluminum profiles 6-2 are respectively fixed on four adjustable horizontal corner seats 6-1, Two pairs of aluminum profiles 6-2 are fixed in the middle of four vertically placed aluminum profiles 6-2 through corner joints, and the installation method of the top four aluminum profiles 6-2 is the same as above.
所述XY两轴运动导轨7由“工”字形装配的三根导轨7-1(7-2)和两个电机7-3组成。其中两根平行导轨7-1构成X运动轴，与之垂直的导轨7-2构成Y运动轴。X轴的平行导轨7-1固定在水平调整底座6顶部两个铝型材6-2上，Y轴导轨7-2固定在X轴导轨7-1的两个滑台上。两个电机7-3分别与两轴导轨的一端相连，其中X轴导轨7-1通过传动轴实现同步运动。The XY two-axis motion guide rail 7 is composed of three guide rails 7-1 (7-2) assembled in the shape of "I" and two motors 7-3. Wherein two parallel guide rails 7-1 constitute the X motion axis, and the guide rail 7-2 perpendicular to it constitutes the Y motion axis. The parallel guide rails 7-1 of the X axis are fixed on two aluminum profiles 6-2 at the top of the horizontal adjustment base 6, and the Y axis guide rails 7-2 are fixed on two slide tables of the X axis guide rails 7-1. The two motors 7-3 are respectively connected to one end of the two-axis guide rail, wherein the X-axis guide rail 7-1 realizes synchronous movement through the transmission shaft.
所述钢索固定装置安装梁8平行X轴导轨安装固定在水平调整底座6顶部。The installation beam 8 of the cable fixing device is installed and fixed on the top of the horizontal adjustment base 6 parallel to the X-axis guide rail.
所述钢索固定装置9固定安装在钢索固定装置安装梁8上，钢索固定装置9成对使用，其用于调整钢索16的空间位置和将之固定。The cable fixing device 9 is fixedly installed on the cable fixing device installation beam 8, and the cable fixing device 9 is used in pairs, and it is used to adjust the spatial position of the cable 16 and fix it.
所述圆周阵列式弱磁检测传感器2固定于Y轴导轨7-2的滑块上，钢索16从其中心穿过。The circumferential array weak field detection sensor 2 is fixed on the slider of the Y-axis guide rail 7-2, and the steel cable 16 passes through the center thereof.
图3为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器示意图。所述传感器夹持装置11由底座11-1和传感器夹具11-2组成。所述底座11-1固定于Y轴导轨7-2滑台上，它的中部开有飞翼形凹槽，其中两翼凹槽用于固定亥姆霍兹线圈13，中部凹槽用于固定传感器夹具11-2，其翼型槽的一侧有用于固定硬性印制电路板15-1的凹槽和螺纹。所述传感器夹具11-2分上、下两部分，其中下半部分为开有半圆槽的长方体，其底部固定于底座11-1中部的凹槽中，上半部分为带双耳的半圆形结构，其上下两部分通过螺栓固定。Fig. 3 is a schematic diagram of a circular array type magnetic field weakening detection sensor based on a steel cable defect scanning system provided by an embodiment of the present invention. The sensor clamping device 11 is composed of a base 11-1 and a sensor clamp 11-2. The base 11-1 is fixed on the slide table of the Y-axis guide rail 7-2, and its middle part has a flying wing-shaped groove, wherein the two wing grooves are used to fix the Helmholtz coil 13, and the middle groove is used to fix the sensor The clamp 11-2 has grooves and threads for fixing the rigid printed circuit board 15-1 on one side of its airfoil groove. The sensor fixture 11-2 is divided into upper and lower parts, wherein the lower part is a cuboid with a semicircular groove, the bottom of which is fixed in the groove in the middle of the base 11-1, and the upper part is a semicircular shape with two ears. Shaped structure, the upper and lower parts are fixed by bolts.
所述传感器夹具11-2上下两部分配合夹紧分体式磁屏蔽壳12的中部；亥姆霍兹线圈13的两个线圈分别套在分体式磁屏蔽壳12的两端并固定于底座11-1的翼形凹槽内。The upper and lower parts of the sensor clamp 11-2 cooperate to clamp the middle part of the split-type magnetic shielding shell 12; the two coils of the Helmholtz coil 13 are respectively set on the two ends of the split-type magnetic shielding shell 12 and fixed on the base 11- 1 in the wing-shaped groove.
所述印制电路板15分为硬性印制电路板(PCB)15-1和柔性印制电路板(FPC)15-2，FPC15-2一端焊接隧道磁阻元件14-1，一端连接PCB15-1。所述PCB15-1采用3V纽扣电池作为电源并通过降压电路为隧道磁阻元件14-1提供1V直流电压，其分别与FPC15-2和数据采集单元5相连。The printed circuit board 15 is divided into a rigid printed circuit board (PCB) 15-1 and a flexible printed circuit board (FPC) 15-2, one end of the FPC15-2 is welded to the tunnel magnetoresistive element 14-1, and one end is connected to the PCB15- 1. The PCB15-1 uses a 3V button battery as a power source and provides a 1V DC voltage for the tunnel magnetoresistive element 14-1 through a step-down circuit, which is connected to the FPC15-2 and the data acquisition unit 5 respectively.
图4为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器径向剖视图。所述传感器固定环14-2为管状结构，其与分体式磁屏蔽壳12内腔过渡配合，其外壁沿周向均匀分布N(N≥2)个凹槽。所述隧道磁阻元件14-1均匀分布于传感器固定环14-2的凹槽内。所述钢索16、传感器固定环14-2、分体式磁屏蔽壳12、亥姆霍兹线圈13和传感器夹具11-2同轴装配。Fig. 4 is a radial sectional view of the circumferential array weak magnetic detection sensor of the steel cable defect scanning system based on the circumferential array weak magnetic detection sensor provided by the embodiment of the present invention. The sensor fixing ring 14 - 2 is a tubular structure, which transition fits with the inner cavity of the split magnetic shielding shell 12 , and N (N≥2) grooves are evenly distributed on its outer wall along the circumferential direction. The tunnel magnetoresistive elements 14-1 are uniformly distributed in the groove of the sensor fixing ring 14-2. The steel cable 16, the sensor fixing ring 14-2, the split magnetic shielding shell 12, the Helmholtz coil 13 and the sensor fixture 11-2 are coaxially assembled.
图5为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统圆周阵列式弱磁检测传感器轴向剖视图。所述亥姆霍兹线圈13的两个线圈串联且电流方向一致。所述传感器固定环14-2的内径比分体式磁屏蔽壳12端盖的内径小1mm～2mm，比被测钢索16直径大1mm～2mm。其内表面沿周向均匀分布N个深0.5mm～1mm、宽1mm～2mm从传感器支撑一端延伸至其中部深0.5mm～1mm的浅槽，浅槽与外壁凹槽位置相对并相互连通。所述隧道磁阻元件14-1通过胶封固定于传感器固定环14-2的凹槽内，所述FPC15-2一端焊接隧道磁阻元件14-1，一端连接PCB15-1，其穿过传感器固定环14-2连通内外壁凹槽的方孔，并胶封保护于传感器固定环14-2内壁的浅槽内。Fig. 5 is an axial cross-sectional view of a circumferential array type field weakening detection sensor based on a steel cable defect scanning system provided by an embodiment of the present invention. The two coils of the Helmholtz coil 13 are connected in series with the same current direction. The inner diameter of the sensor fixing ring 14 - 2 is 1 mm to 2 mm smaller than the inner diameter of the end cover of the split magnetic shielding shell 12 , and is 1 mm to 2 mm larger than the diameter of the steel cable 16 to be tested. N shallow grooves with a depth of 0.5 mm to 1 mm and a width of 1 mm to 2 mm are evenly distributed along the inner surface along the circumference, extending from one end of the sensor support to the middle of the sensor with a depth of 0.5 mm to 1 mm. The tunnel magneto-resistance element 14-1 is fixed in the groove of the sensor fixing ring 14-2 by glue sealing, one end of the FPC15-2 is welded to the tunnel magneto-resistance element 14-1, and the other end is connected to the PCB15-1, which passes through the sensor The fixing ring 14-2 communicates with the square holes of the grooves on the inner and outer walls, and is sealed and protected in the shallow groove on the inner wall of the sensor fixing ring 14-2.
如图6所示，图6为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统钢索固定装置示意图。所述钢索固定装置9由固定底座9-1、支架9-2和固定螺栓9-3组成。固定底座9-1固定安装在钢索固定装置安装梁8上，支架9-2由“工”字形和“回”字形结构组装而成，四个固定螺栓9-3分别从“回”形支架9-2四个方向穿过指向中心。钢索16从“回”字形支架9-2中心穿过，通过拧动螺栓可调整钢索空间位置并夹紧固定钢索。As shown in FIG. 6 , FIG. 6 is a schematic diagram of a steel cable fixing device for a steel cable defect scanning system based on a circumferential array type magnetic field weakening detection sensor provided by an embodiment of the present invention. Described cable fixing device 9 is made up of fixing base 9-1, support 9-2 and fixing bolt 9-3. The fixed base 9-1 is fixedly installed on the installation beam 8 of the steel cable fixing device, the support 9-2 is assembled by the "I" shape and the "back" shape structure, and the four fixing bolts 9-3 are connected from the "back" shape support respectively 9-2 The four directions pass through and point to the center. Wire rope 16 passes from " back " font support 9-2 center, can adjust wire rope space position and clamp and fix wire rope by twisting bolt.
如图7所示，图7为本发明实施例提供的基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统同轴装配示意图。所述钢索夹持组件3包括钢索固定装置9和钢索预紧装置10。所述钢索预紧装置10由穿心式液压泵10-1、挡板10-2、刚性底座10-3和锚头10-4组成。As shown in Fig. 7, Fig. 7 is a schematic diagram of the coaxial assembly of the wire rope defect scanning system based on the circumferential array type weak magnetic detection sensor provided by the embodiment of the present invention. The cable clamping assembly 3 includes a cable fixing device 9 and a cable pretensioning device 10 . The cable pretensioning device 10 is composed of a through-hole hydraulic pump 10-1, a baffle plate 10-2, a rigid base 10-3 and an anchor head 10-4.
基于圆周阵列式弱磁检测传感器的钢索缺陷扫查系统同轴装配方法如下：角座6-1调整系统水平，圆周阵列式弱磁检测传感器2通过Y轴导轨运动到钢索固定装置安装梁8正上方，钢索预紧装置10安装于水平调整底座6两侧，并且锚头10-4、挡板槽10-2、穿心式液压泵10-1、钢索固定装置的“回”形支架9-2和圆周阵列式弱磁检测传感器2中心位于一条直线上。钢索预紧装置10将钢索16拉伸至准直状态，钢索固定装置9通过四个固定螺栓9-3调整钢索16的空间位置并夹紧固定。The coaxial assembly method of the steel cable defect scanning system based on the circumferential array weak magnetic detection sensor is as follows: the corner seat 6-1 adjusts the system level, and the circumferential array weak magnetic detection sensor 2 moves to the installation beam of the steel cable fixing device through the Y-axis guide rail 8, the cable pretensioning device 10 is installed on both sides of the horizontal adjustment base 6, and the anchor head 10-4, the baffle groove 10-2, the through-hole hydraulic pump 10-1, and the "back" of the cable fixing device The centers of the shaped support 9-2 and the circumferential array type magnetic field weakening detection sensor 2 are located on a straight line. The steel cable pretensioning device 10 stretches the steel cable 16 to an aligned state, and the steel cable fixing device 9 adjusts the spatial position of the steel cable 16 through four fixing bolts 9-3 and clamps and fixes it.
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