CN111141817A - Stranded wave noise elimination device for nondestructive testing of steel wire rope - Google Patents
Stranded wave noise elimination device for nondestructive testing of steel wire rope Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 79
- 239000010959 steel Substances 0.000 title claims abstract description 79
- 238000009659 non-destructive testing Methods 0.000 title claims abstract description 18
- 230000008030 elimination Effects 0.000 title claims abstract description 10
- 238000003379 elimination reaction Methods 0.000 title claims abstract description 10
- 230000007547 defect Effects 0.000 description 24
- 230000005291 magnetic effect Effects 0.000 description 24
- 239000000523 sample Substances 0.000 description 16
- 238000001514 detection method Methods 0.000 description 15
- 238000000034 method Methods 0.000 description 13
- 230000008569 process Effects 0.000 description 9
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000012360 testing method Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 4
- 230000005284 excitation Effects 0.000 description 3
- 239000003302 ferromagnetic material Substances 0.000 description 3
- 230000006698 induction Effects 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 238000003672 processing method Methods 0.000 description 3
- 238000005299 abrasion Methods 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 230000007774 longterm Effects 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 238000005070 sampling Methods 0.000 description 2
- 230000035945 sensitivity Effects 0.000 description 2
- 230000001960 triggered effect Effects 0.000 description 2
- BGPVFRJUHWVFKM-UHFFFAOYSA-N N1=C2C=CC=CC2=[N+]([O-])C1(CC1)CCC21N=C1C=CC=CC1=[N+]2[O-] Chemical compound N1=C2C=CC=CC2=[N+]([O-])C1(CC1)CCC21N=C1C=CC=CC1=[N+]2[O-] BGPVFRJUHWVFKM-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000004069 differentiation Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/83—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields
- G01N27/85—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws by investigating stray magnetic fields using magnetographic methods
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R33/00—Arrangements or instruments for measuring magnetic variables
- G01R33/02—Measuring direction or magnitude of magnetic fields or magnetic flux
- G01R33/10—Plotting field distribution ; Measuring field distribution
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Abstract
The invention discloses a strand wave noise elimination device for nondestructive testing of a steel wire rope, which comprises an angle encoder and three groups of sensors, namely a sensor group A, a sensor group B and a sensor group C, wherein the three groups of sensors are tightly pressed on the surface of the steel wire rope to be tested through springs; each group of sensors are circumferentially and uniformly distributed on the surface of the steel wire rope to be detected, and the axial distance between the sensor group A and the sensor group C is one strand wave period of the steel wire rope to be detected; the idler wheel of the angle encoder is in contact with the surface of the steel wire rope to be detected, the idler wheel triggers acquisition instructions of the sensor group at equal angles, and therefore strand wave noise is eliminated according to the difference of output signals of the sensor group A and the sensor group C.
Description
Technical Field
The invention belongs to the technical field of nondestructive testing, and particularly relates to a strand wave noise elimination device for nondestructive testing of a steel wire rope.
Background
The steel wire rope has the advantages of high strength, light dead weight, good elasticity, stable and reliable work, capability of running under high-speed working conditions and the like, and is widely used as a key part for lifting, transporting and bearing the weight of equipment. In the long-term operation process of the steel wire rope, the steel wire rope is influenced by environmental corrosion, uncertain alternating load, mechanical impact, abrasion and the like, damages such as broken wires, abrasion, corrosion and the like can occur, the steel wire rope is reduced in strength and even suddenly broken due to long-term accumulation, the production is stopped slightly, and people are damaged and killed if the steel wire rope is damaged mechanically.
Theoretically, a plurality of nondestructive testing methods for the steel wire rope are discussed, only electromagnetic testing methods are practiced and popularized at present, and the basic principle of the most widely applied nondestructive testing method for the leakage flux is as follows: the steel wire rope is magnetized to be in magnetic saturation by using an exciting device, a leakage magnetic field is generated at the discontinuous part of the steel wire rope, a magnetic sensor (such as an induction coil, a Hall sensor or a magnetic resistance sensor) is used for detecting a surface magnetic signal of the steel wire rope, and the steel wire rope defect is characterized and identified through the leakage magnetic signal.
The detection basic principle of the steel wire rope magnetic flux leakage nondestructive detection is shown in figure 1, the steel wire rope belongs to a ferromagnetic material, the steel wire rope is excited by a permanent magnet to magnetic saturation, a magnetic loop is formed in the permanent magnet, industrial pure iron, an air gap and a steel wire rope section to be detected in the excitation process, and if the material is continuous and uniform, magnetic induction lines almost pass through the ferromagnetic material; if the material has defects, the magnetic induction line distribution near the defects changes due to small magnetic conductivity and large magnetic resistance of the defects, a leakage magnetic field is formed on the surface of the ferromagnetic material, and the leakage magnetic field is detected by using a magnetic sensor (the higher the sensitivity of the sensor is, the better the accuracy of the detection result is, the smaller the volume of the sensor is, the better the sensor can be matched with the surface structure of the steel wire rope), so the invention uses a latest generation of magnetoresistive sensor-TMR sensor as a description for a method, and the sensor has the advantages of small volume, high sensitivity and the like).
The existing method for carrying out nondestructive testing on the steel wire rope by detecting a magnetic leakage signal has the following problems: the steel wire rope is formed by twisting a plurality of steel wires, so that periodic strand waves are formed on the surface of the steel wire rope, when the detection probe moves on the surface of the steel wire rope, the distance between the surface of the sensor and the surface of the steel wire rope also periodically fluctuates along with the strand waves, and therefore, the magnetic field value on the surface of the steel wire rope tested by the sensor also periodically fluctuates along with the twisting period of the strand ropes due to the structural influence of the strand ropes, so that the detection capability of the steel wire rope nondestructive detection probe on defects is influenced to a great extent, and magnetic leakage signals of the defects are possibly submerged by strand wave signals, and further, the missed judgment and the erroneous judgment are caused.
Disclosure of Invention
In view of this, the invention provides a strand wave noise elimination device for nondestructive testing of a steel wire rope, which can eliminate strand wave noise of the steel wire rope in the nondestructive testing process.
The technical scheme for realizing the invention is as follows:
a strand wave noise elimination device for nondestructive testing of a steel wire rope comprises an angle encoder and three groups of sensors which are tightly pressed on the surface of the steel wire rope to be tested through springs, namely a sensor group A, a sensor group B and a sensor group C;
each group of sensors are circumferentially and uniformly distributed on the surface of the steel wire rope to be detected, and the axial distance between the sensor group A and the sensor group C is one strand wave period of the steel wire rope to be detected;
the idler wheel of the angle encoder is in contact with the surface of the steel wire rope to be detected, the idler wheel triggers acquisition instructions of the sensor group at equal angles, and therefore strand wave noise is eliminated according to the difference of output signals of the sensor group A and the sensor group C.
Furthermore, the number of the sensors in the sensor group is set according to the resolution of the sensors and the diameter of the steel wire rope to be detected.
Has the advantages that:
the invention utilizes the spring to compress the sensor probe, ensures that the lifting distance between the sensor and the surface of the steel wire rope is kept constant, and the output result of the sensor is not influenced by the strand wave noise formed by the fluctuation of the lifting distance between the sensor and the surface of the steel wire rope.
According to the invention, two groups of differential sensors are arranged according to the periodic arrangement of the steel wire strand waves, so that the problem that the output signals of the sensors are periodically fluctuated along with the strand waves due to the strand waves on the surfaces of the sensors and the steel wire rope is solved, and meanwhile, the influence of the uneven noise of the magnetic field caused by the steel wire rope strand on the actual detection result is also eliminated.
Drawings
FIG. 1 is a diagram of the basic principle of nondestructive testing.
FIG. 2 is a schematic view of the structure of the apparatus of the present invention.
FIG. 3 is a cross-sectional view of the device of the present invention.
Fig. 4 shows a sensor data acquisition process and a data processing method.
FIG. 5 is a comparison of the output of a sensor probe under conventional conditions with the output of a sensor of the apparatus of the present invention.
Wherein, 1-an angle encoder; 2-a spring; 3-a spring catch barrel; 4-steel wire rope to be detected; 5-permanent magnet; 6-high permeability material (industrial pure iron or armature); 7-sensor group A; 8-sensor group B; 9-sensor group C.
Detailed Description
The invention is described in detail below by way of example with reference to the accompanying drawings.
The invention provides a strand wave noise elimination device for nondestructive testing of a steel wire rope, which comprises the following components as shown in figures 2 and 3: the device comprises an angle encoder 1, a spring 2, a spring catch 3, a steel wire rope 4 to be detected, a permanent magnet 5, a high-permeability material (industrial pure iron or armature) 6, a sensor group A7, a sensor group B8 and a sensor group C9. Wherein 4, 5 and 6 form the excitation device part of the probe, 7, 8 and 9 are probe detection device parts, and 1, 2 and 3 are probe auxiliary function parts.
An angle encoder: the basic principle of the angle encoder is that the encoder sends out pulse signals after rotating by a fixed angle, the principle can be applied to ranging of a steel wire rope and control instructions of collecting commands of a sensor, time and voltage amplitude signals are converted into the relation between a rotating angle and the voltage amplitude, and the interference of influence on detection results caused by uneven running speed between the steel wire rope and a probe in the detection process can be effectively removed. The trigger is triggered at an equal angle, so that the rotating angle of the trigger wheel can be calculated through the number of the collected data, the relative movement distance between the trigger wheel and the steel wire rope is fixed when the trigger wheel rotates by a fixed angle, and the defect damage position of the steel wire rope can be positioned by converting the angle of the defect signal position. The angle encoder is directly connected with the adjacent permanent magnet through the fixed rod, the idler wheel of the angle encoder is in surface contact with the steel wire rope, and the rotating energy is provided for the angle encoder through the friction force of relative movement of the steel wire rope.
A spring: in the detection process, the spring is fixed in the spring retaining cylinder and is in a compression state, in the relative movement process of the probe and the steel wire rope, the spring plays a role in compressing and supporting the sensor, the sensor is periodically changed along with the fluctuation of strand waves on the surface of the steel wire rope, the lifting distance between the sensor and the surface of the steel wire rope is kept constant, and the output result of the sensor is not influenced by the strand wave noise formed by the fluctuation of the lifting distance between the sensor and the surface of the steel wire rope.
Sensor group A, B, C: the sensor array is located inside the excitation device. The layout of the sensor is one of the key points of the steel wire rope nondestructive testing device, and the layout mode of the sensor determines the detection precision and the resolution of the device to a certain extent. The device adopts a vector magnetic sensor (such as a TMR magnetic sensor) to detect the axial leakage magnetic field of the steel wire rope, and is provided with A, B, C three groups of sensors, wherein a sensor group A, C is a differential sensor, the sensor group is in annular layout, and the layout number of the sensors is correspondingly designed according to the resolution requirement of a probe and the diameter of the steel wire rope.
A. And the layout distance of the two groups of sensors corresponds to one strand wave period of the steel wire rope, and the hardware noise elimination of the strand wave noise of the steel wire rope is realized by utilizing the differential output result of the two groups of sensors. In the result output after the difference, two characteristic defect signals appear on the same defect, and the two output results of the same defect are respectively as follows: the phase of the two defect signals after the difference is carried out differs by one strand wave period, and the amplitudes of the two signals are opposite, so that in the actual data processing process, the two signals with opposite amplitudes of the difference result in one strand wave period are regarded as a defect.
The B group of sensors are output results of an original steel wire rope nondestructive testing device and can be used as statistical sensors of the number of defects, and because the A, C sensors eliminate the strand wave noise after differential output, two characteristic output values with equal size and opposite directions are output for the same defect, the B sensors can be used as a reference signal of A, C differential data to perform statistics on the actual number of defects. In addition, because the steel wire rope nondestructive detection is carried out under the condition of detecting the position of the defect, the situation that the defect occurs under the A, C sensor at the same time can occur, and the mode of outputting the defect through difference is likely to cause the miss judgment of the defect (for example, after A, C difference, the output is a straight line, but after B passes through measurement, two defect characteristic signals appear on one strand wave period, which indicates that A, C defects with basically the same size exist at two positions at the same time).
Fig. 4 shows a sensor data acquisition flow and a data processing method, the output signal of the TMR sensor may be subjected to data acquisition and analog-to-digital conversion by an NI acquisition card and LabVIEW software, and data differentiation is implemented in a LabVIEW program diagram, and finally the differentiated result and the B-group test result are displayed in a LabVIEW interface.
Fig. 5 is a diagram showing the test results and the effect of the difference results of a pair of sensors, in which when the group a sensors detect a defect, the detected signals of the group C sensors are waveforms of undamaged positions that are different from the position of the defect by one strand period, so that the noise reduction of the steel wire strand wave noise can be realized by the data processing method in fig. 5.
When the damage condition of the steel wire rope is measured, the axial component of the leakage magnetic field on the surface of the steel wire rope is obtained by the relative motion between the test probe and the steel wire rope. The device is firstly sleeved on a steel wire rope to be tested, and then power is supplied to a TMR sensor coil. The specific process is as follows:
(1) opening a detection probe, placing a detected steel wire rope into the detection probe, closing the probe, buckling a buckle, and supplying 5V power to the sensor array;
(2) starting a LabVIEW data acquisition program, and setting a sampling rate and a sampling mode;
(3) the probe is slid to enable the probe and the steel wire rope to move relatively, and then the sensor array can be acquired and triggered through the angle encoder;
(4) and displaying the data through a front panel icon of LabVIEW, and further interpreting the result of the nondestructive testing of the steel wire rope to finish the testing.
In summary, the above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (2)
1. A strand wave noise elimination device for nondestructive testing of a steel wire rope is characterized by comprising an angle encoder and three groups of sensors which are tightly pressed on the surface of the steel wire rope to be tested through springs, wherein the sensors are a sensor group A, a sensor group B and a sensor group C;
each group of sensors are circumferentially and uniformly distributed on the surface of the steel wire rope to be detected, and the axial distance between the sensor group A and the sensor group C is one strand wave period of the steel wire rope to be detected;
the idler wheel of the angle encoder is in contact with the surface of the steel wire rope to be detected, the idler wheel triggers acquisition instructions of the sensor group at equal angles, and therefore strand wave noise is eliminated according to the difference of output signals of the sensor group A and the sensor group C.
2. The strand noise elimination device for the nondestructive testing of the steel wire rope according to claim 1, wherein the number of the sensors in the sensor group is set according to the resolution of the sensors and the diameter of the steel wire rope to be tested.
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| CN201911358693.0A CN111141817A (en) | 2019-12-25 | 2019-12-25 | Stranded wave noise elimination device for nondestructive testing of steel wire rope |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112083058A (en) * | 2020-08-18 | 2020-12-15 | 长江三峡通航管理局 | Signal acquisition and processing device suitable for broken wire detection of steel wire rope of multi-row pulley block |
| CN112902821A (en) * | 2021-01-08 | 2021-06-04 | 电子科技大学 | Method for measuring lay length on line and evaluating health state of steel wire rope according to lay length |
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| JP2005156419A (en) * | 2003-11-27 | 2005-06-16 | Ishikawajima Harima Heavy Ind Co Ltd | Magnetic flaw detecting device for wire rope |
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| WO2011148456A1 (en) * | 2010-05-25 | 2011-12-01 | 三菱電機株式会社 | Wire rope flaw detection device |
| CN103760222A (en) * | 2014-01-18 | 2014-04-30 | 中国矿业大学 | Mining steel wire rope online detection device and method based on giant magnetoresistance sensor array |
| CN106841379A (en) * | 2017-01-11 | 2017-06-13 | 兰州空间技术物理研究所 | A kind of steel wire nondestructive detection device |
| CN108535354A (en) * | 2018-04-13 | 2018-09-14 | 哈尔滨工业大学深圳研究生院 | A kind of damaging judge and localization method of steel wire rope Magnetic Flux Leakage Inspecting and magnetic transmitting detection |
| CN109283244A (en) * | 2018-08-01 | 2019-01-29 | 昆明理工大学 | A kind of wirerope non-destructive detection device based on TMR Magnetic Sensor |
-
2019
- 2019-12-25 CN CN201911358693.0A patent/CN111141817A/en active Pending
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005156419A (en) * | 2003-11-27 | 2005-06-16 | Ishikawajima Harima Heavy Ind Co Ltd | Magnetic flaw detecting device for wire rope |
| US20100182000A1 (en) * | 2009-01-22 | 2010-07-22 | Mitsubishi Electric Corporation | Wire-rope flaw detector |
| WO2011148456A1 (en) * | 2010-05-25 | 2011-12-01 | 三菱電機株式会社 | Wire rope flaw detection device |
| CN103760222A (en) * | 2014-01-18 | 2014-04-30 | 中国矿业大学 | Mining steel wire rope online detection device and method based on giant magnetoresistance sensor array |
| CN106841379A (en) * | 2017-01-11 | 2017-06-13 | 兰州空间技术物理研究所 | A kind of steel wire nondestructive detection device |
| CN108535354A (en) * | 2018-04-13 | 2018-09-14 | 哈尔滨工业大学深圳研究生院 | A kind of damaging judge and localization method of steel wire rope Magnetic Flux Leakage Inspecting and magnetic transmitting detection |
| CN109283244A (en) * | 2018-08-01 | 2019-01-29 | 昆明理工大学 | A kind of wirerope non-destructive detection device based on TMR Magnetic Sensor |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN112083058A (en) * | 2020-08-18 | 2020-12-15 | 长江三峡通航管理局 | Signal acquisition and processing device suitable for broken wire detection of steel wire rope of multi-row pulley block |
| CN112083058B (en) * | 2020-08-18 | 2024-03-12 | 长江三峡通航管理局 | Signal acquisition and processing device suitable for multi-row pulley block steel wire rope broken wire detection |
| CN112902821A (en) * | 2021-01-08 | 2021-06-04 | 电子科技大学 | Method for measuring lay length on line and evaluating health state of steel wire rope according to lay length |
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Application publication date: 20200512 |