CN112378991A - Steel wire rope detector with replaceable lining - Google Patents
Steel wire rope detector with replaceable lining Download PDFInfo
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- CN112378991A CN112378991A CN202011342692.XA CN202011342692A CN112378991A CN 112378991 A CN112378991 A CN 112378991A CN 202011342692 A CN202011342692 A CN 202011342692A CN 112378991 A CN112378991 A CN 112378991A
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- 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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
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Abstract
The invention relates to the technical field of steel wire rope detection, and discloses a detection method of a detector and an internal structure of the detector. The invention arranges the lining slightly larger than the diameter of the steel wire rope, so that the instrument realizes good centering performance. The inner lining and the outer lining are matched with each other, so that the steel wire ropes with different rope diameters can be detected, and the universality of the instrument is improved. The concave station is arranged at the outer lining and the installation space of the flat cable flexible board is reserved in the matching of the concave station and the inner lining, so that the defect that the distance between a steel wire rope and a detection element in a roller type steel wire rope detector is far can be overcome, and the detection precision is high. The installation space of the flat cable flexible board is reserved in the matching, the installation is convenient, and the full-phase arrangement of the detection elements can be realized. The invention detects the radial vector of the magnetic leakage signal of the steel wire rope, when the steel wire rope is not damaged, the value of the radial vector of the signal is zero, and only when the damage exists, the radial vector of the magnetic leakage signal exists, thereby overcoming the problem that the collected axial vector can exceed the measuring range of a detection element in the prior art.
Description
Technical Field
The invention relates to the technical field of nondestructive testing of steel wire ropes, in particular to a steel wire rope detector with a replaceable lining.
Background
The steel wire rope has the advantages of high tensile strength, light dead weight, good elasticity, stable and reliable work, strong dynamic load bearing and overload bearing capacity and the like, and is widely applied to various departments of national economic construction such as coal mines, non-coal mines, ports, bridges, ropeways, elevators and the like in China. However, as an engineering bearing device, the steel wire rope is often influenced by complex working conditions and environments such as bending fatigue, abrasion, alternating load, mechanical impact and corrosion in the operation process, and the phenomena such as wire breakage, abrasion, deformation and corrosion inevitably occur, so that potential safety hazards exist. The damage condition and the bearing capacity of the device are directly related to the safety of personnel and production.
Therefore, in order to ensure the safe and reliable operation of the steel wire rope, experts and scholars at home and abroad are always exploring a nondestructive testing method for the steel wire rope. Among them, the electromagnetic detection method is currently recognized as one of the most practical detection methods.
Among the wire rope detecting instrument that exists at present, adopt the gyro wheel mode to solve wire rope and receive the eccentric problem between the wire rope that the permanent magnet adsorbs the wire rope that causes and the instrument mostly, do like the real novel patent portable wire rope detection device (CN208313892U) and the utility model patent wire rope detector subassembly (CN207163809U), but, can appear wire rope apart from hall element farther problem when detecting the less wire rope of rope footpath to cause and detect the precision poor, or can not detect the signal scheduling problem.
In the existing steel wire rope detection instrument, most of the detection is axial magnetic leakage signals, the direction of the magnetic leakage signals is consistent with the direction of a magnetic field inside a steel wire rope, and the magnetic saturation condition of a Hall element is easily caused, namely the magnetic saturation condition exceeds the detection range of the Hall element.
The accident that the detection instrument is taken away by the steel wire rope occurs on the detection site, and the reason is that the steel wire rope at a certain position is twisted to cause overlarge rope diameter and cannot smoothly pass through the detection instrument.
Disclosure of Invention
In view of this, the invention provides a steel wire rope detector with a replaceable lining, which can be universally used for different rope diameters, can realize high-precision detection on steel wire ropes with different rope diameters, and is simple and convenient to install.
The invention has four radial permanent magnets, the direction of the magnetic force line is radial, and the four radial permanent magnets magnetize the steel wire rope, so that a stronger magnetic field passes through the steel wire rope. The permanent magnet, the steel wire rope and the shell are used for realizing a complete magnetic line of force passage in the instrument. The steel wire rope with a strong magnetic field is communicated inside, when the steel wire rope is damaged by wire breakage and the like, the magnetic field overflows from the damaged part, and the health condition of the steel wire rope is detected through the overflowing magnetic field.
In the process of detecting the steel wire rope, the steel wire rope is easily adsorbed by a permanent magnet in an instrument, so that the eccentricity is caused; the invention is provided with the lining slightly larger than the diameter of the steel wire rope, so that the instrument can realize good centering performance.
The inner lining and the outer lining are matched with each other, so that the detection of the steel wire ropes with different rope diameters can be finished, the distance between the steel wire rope and the Hall element can be kept while the detection of different rope diameters is adapted, the defect that the steel wire rope is far away from the Hall element in a roller type steel wire rope detector can be overcome, and the detection precision is high.
According to the invention, the inner lining and the outer lining are matched with each other, and the installation space of the flat cable flexible board is reserved in the matching process, so that the full-phase arrangement of Hall elements can be realized, and the full-phase high-precision detection of the health condition of the steel wire rope is completed.
The Hall element and the flexible printing plate are arranged in parallel and used for detecting the radial vector of the magnetic flux leakage signal of the steel wire rope. When no damage exists on the steel wire rope, the numerical value of the radial vector of the magnetic leakage signal of the steel wire rope is zero, namely the initial magnetic field intensity of the detection input of the Hall element is zero, and the magnetic field intensity changes only when the damage exists. At present, most of steel wire rope detection instruments adopt a mode of detecting the axial magnetic field intensity, and because a permanent magnet in the detection instrument is strong magnetic, when a steel wire rope is not damaged, a larger signal is still input in the direction, so that the magnetic saturation condition of a Hall element is easily caused, namely the magnetic saturation condition exceeds the detection range of the Hall element.
The anti-collision pin is made of fragile PVC materials, so that the situation that the diameter of the steel wire rope is increased due to kinking and the like is prevented, when the situation occurs and excessive tensile force is applied to the instrument, the anti-collision pin is broken, the safety of the instrument can be ensured, and more economic losses are prevented. Meanwhile, the end part of the small lining is provided with a chamfer, so that the smooth passing of the steel wire rope is guaranteed.
Drawings
FIG. 1 is an external view of the present invention;
FIG. 2 is an internal configuration diagram of the open state of the apparatus of the present invention;
FIG. 3 is a schematic diagram of the arrangement of Hall elements in a flat flexible printed circuit board according to the present invention;
FIG. 4 shows an inner liner, an outer liner, and a bump pin used in detecting a small-gauge wire rope in the inner liner-replaceable wire rope detector;
FIG. 5 shows an inner liner, an outer liner, and a bump pin used in detecting a large-diameter wire rope in the inner liner-replaceable wire rope detector;
FIG. 6 is an exploded view of the present invention;
the figures are labeled as follows: the permanent magnet assembly comprises left radial permanent magnets (11, 12), right radial permanent magnets (21, 22), separators (31, 32), outer linings (41, 42), inner linings (51, 52), an upper shell (61), a lower shell (62), upper end plates (71, 72), lower end plates (81, 82), Hall elements (91, 92 … …), a flat flexible board (10), a handle (00) and anti-collision pins (01, 02).
Detailed Description
The invention provides a steel wire rope detector with a replaceable lining, which comprises:
the permanent magnet structure comprises two permanent magnets, namely a left radial permanent magnet (11, 12) and a right radial permanent magnet (21, 22), wherein 11 and 12 in the left radial permanent magnet (11, 12) belong to two same parts which can be interchanged, and 21 and 22 in the right radial permanent magnet (21, 22) belong to two same parts which can be interchanged. The left radial permanent magnets (11, 12) and the right radial permanent magnets (21, 22) are different in that the directions of magnetic lines of force of the two permanent magnets are opposite, namely when the magnetic lines of force of the left radial permanent magnets (11, 12) point to the axis, the magnetic lines of force of the radial permanent magnets (21, 22) point to the direction far away from the axis, and when the magnetic lines of force of the left radial permanent magnets (11, 12) point to the direction far away from the axis, the magnetic lines of force of the right radial permanent magnets (21, 22) point to the axis. A closed magnetic line loop is formed among the left radial permanent magnet (11), the upper shell (61), the right radial permanent magnet (21) and the steel wire rope, and a closed magnetic line loop is formed among the left radial permanent magnet (12), the lower shell (62), the right radial permanent magnet (22) and the steel wire rope. In the invention, except that the left radial permanent magnet (11), the left radial permanent magnet (12), the right radial permanent magnet (21) and the right radial permanent magnet (22) are permanent magnets, the upper shell (61) and the lower shell (62) are magnetic conductive materials, and the rest parts are non-magnetic conductive materials.
The separators (31, 32) are two pieces of non-magnetically conductive material, the two pieces being the same two pieces. The separator (31) is used for separating the left radial permanent magnet (11) from the right radial permanent magnet (21), and the separator (32) is used for separating the left radial permanent magnet (12) from the right radial permanent magnet (22). The separator (31) is externally fitted to the upper casing (61) and internally fitted to the outer liner (41); the divider (32) is fitted externally to the lower casing (62) and internally to the outer liner (42). Meanwhile, the separator serves to separate the permanent magnet and the outer liner.
Two magnetic conductivity materials of the upper shell (61) and the lower shell (62) are not two identical parts, the upper shell (61) needs to fix the handle (00), a structure required by the fixed handle (00) is reserved, and the lower shell does not need. The magnetic conductive material upper shell (61) is used for coating the left radial permanent magnet (11) and the right radial permanent magnet (21) and plays a magnetic conductive role between the two permanent magnets.
The handle (00) is fixed on the upper part of the upper shell (61) and is convenient to install and transport.
The upper end plates (71, 72) are two identical parts. The upper end plate (71) is matched with the upper shell (61), the right radial permanent magnet (21) and the separator (31) and plays a role in fixing the three parts; the upper end plate (72) is matched with the upper shell (61), the left radial permanent magnet (11) and the separator (31) and plays a role in fixing the three parts. The upper end plates (71, 72) are also matched with the outer lining (41), so that the outer lining is convenient to replace, and the device is suitable for detecting steel wire ropes with different rope diameters.
The lower end plates (81, 82) are two identical pieces. The lower end plate (81) is matched with the lower shell (62), the right radial permanent magnet (22) and the separator (32), plays a role in fixing the three parts and is used as a base; the lower end plate (82) cooperates with the lower shell (62), the left radial permanent magnet (12) and the divider (32) and serves to hold these three components together as a base. The lower end plates (81, 82) have the same function as the upper end plates (71, 72), and the outer linings (42) are matched, so that the outer linings can be conveniently replaced, and the device is suitable for detecting steel wire ropes with different rope diameters.
The outer linings (41, 42) are two identical parts, are processed from non-magnetic conductive materials and are important parts for realizing the replaceable inner lining. The end part of the outer lining (41) is attached to the upper end plate (71) and the upper end plate (72) to prevent the steel wire rope in operation from driving the inner lining (51) to drive the outer lining (41) to axially move; the outer circular surface of the outer liner (41) is engaged with the separator (31), and the inner circular surface is engaged with the inner liner (51) and located outside the flat flexible printed circuit board (10). In the same way, the end part of the outer lining (42) is attached to the lower end plates (81, 82) to prevent the steel wire rope in operation from driving the inner lining (52) to drive the outer lining (42) to move axially; the outer circumferential surface of the outer liner (42) is fitted to the separator (32), and the inner circumferential surface is fitted to the inner liner (52) and located outside the flat flexible printed circuit board (10). The inner circle surface radius of the outer linings (41, 42) is determined according to the outer circle surface radius of the inner linings (51, 52), and when the steel wire rope with larger rope diameter is detected, the inner linings (51, 52) with larger inner circle surface radius and larger outer circle surface radius are selected, and the outer linings (41, 42) matched with the inner linings are selected. When the steel wire rope is suitable for steel wire ropes with different rope diameters, the outer circular surfaces of the outer linings (41 and 42) are unchanged, and only the inner circular surfaces are correspondingly adjusted. Boring a hole in the middle of the inner circular surface of the outer liner to serve as an installation space of the flat cable flexible board; in order to ensure the normal installation of the flat cable flexible plate, the radial width of the boring hole is more than 5 mm.
The inner linings (51, 52) are two identical parts, are processed from non-magnetic conductive materials and are also important parts for realizing the replaceable inner lining. The outer circular surface of the inner liner (51) is matched with the outer liner (41), and similarly, the outer circular surface of the inner liner (52) is matched with the outer liner (42). Different liners (51, 52) are replaced according to the wire ropes of different rope diameters, and the outer circular surface and the inner circular surface of each liner vary with the rope diameters of the wire ropes, so that the wire ropes of various rope diameters can be detected by referring to fig. 4 and 5. Meanwhile, chamfers are arranged at the end parts of the linings (51 and 52) to ensure that the steel wire rope smoothly passes through.
The flat flexible printed circuit board (10) and the Hall elements (91, 92 … … 98) are integrated and are core parts for realizing steel wire rope detection. The hall elements (91, 92 … … 98) are replaced by hall elements (9) in the following. The Hall element (9) is welded on a flat flexible board (10) with a special circuit, and then is inserted into the gaps of the inner linings (51, 52) and the outer linings (41, 42) in a bending mode, and finally a whole circle is enclosed. Through the mode, the Hall elements complete the detection of the full phase of the steel wire rope, and the number of the Hall elements required at the whole circle position is determined according to the diameter of the steel wire rope and the preset detection precision. The flat cable flexible board (10) is made of FPC-like materials, so that the flat cable flexible board is convenient to bend and deform. The flat flexible printed circuit (10) with the Hall elements arranged in the full phase can complete power supply and signal output of the Hall elements (9). For the joints of the flat flexible printed circuit board (10), spaces can be reserved at the outer linings (41, 42) and joints for power supply input and signal output are arranged. The joint position of the flat cable flexible board (10) can also be lengthened to directly penetrate through the gap between the upper and lower joint surfaces of the instrument, namely the gap between the outer linings (41 and 42), the gap between the separators (31 and 32) and the gap between the upper shell (61) and the lower shell (62), and the joint is led to the outside of the detector to complete power supply and signal transmission. As for the relation between the Hall elements (9) and the flat flexible board (10), it can be seen from FIG. 3 that the number and the spacing of the Hall elements are determined according to the actual requirement. In fig. 3, hall elements are arranged on only the upper edge of the flexible flat cable (10), and according to actual requirements, hall elements can also be arranged on the lower edge, so that the arrangement of double rows of hall elements is realized, and appropriate mathematical operation can be performed on signals detected by the left and right rows of hall elements, so as to obtain more comprehensive health condition information of the steel wire rope; the other row of Hall elements can also be used as spare elements.
The anti-collision pins (01, 02) are anti-collision devices, the anti-collision pin (01) is arranged between the inner liner (51) and the outer liner (41), and the anti-collision pin (02) is arranged between the inner liner (52) and the outer liner (42). The anti-collision pins (01, 02) are made of special fragile PVC materials, the diameter of each anti-collision pin is 3-4 mm, and the shearing strength is guaranteed to be 30-50 MPa. When the diameter of the steel wire rope is too large and the steel wire rope cannot smoothly pass through the linings (51 and 52), the steel wire rope can break the anti-collision pins (01 and 02) and drive the linings (51 and 52) to move forwards, so that the steel wire rope is prevented from driving the whole instrument to move forwards; the safety of the instrument can be ensured, and more economic losses can be prevented.
The Hall element (9) outputs a voltage signal related to the magnetic field intensity, and the voltage signal is weak and belongs to the millivolt level. The voltage signal detected by the single-row or double-row hall element can be processed properly by adopting a circuit mode, for example: amplifying, filtering, adding and subtracting, and the like, and then accessing to signal display and storage equipment such as an oscilloscope, a data acquisition card and the like, so as to complete the data acquisition and display work of the leakage magnetic signal.
The lining type structure ensures the coaxiality of the steel wire rope in detection, and prevents the eccentric problem caused by the suction force of the permanent magnet to the steel wire rope, thereby influencing the detection precision.
In the process of selecting linings (51, 52) with different diameters to adapt to the diameter of the steel wire rope, the linings (51, 52) with smaller diameters are selected as much as possible to ensure high-precision detection of magnetic leakage signals. The invention has the advantages that the closer distance between the Hall element and the surface of the steel wire rope can be still ensured when the diameter of the steel wire rope is changed, and the high detection precision is ensured.
The flat flexible printed circuit board with special circuits is arranged at the central boring hole of the inner circle surface of the outer linings (41, 42). The flexible flat cable is straight under the state of no stress, is bent when being installed in a detection instrument, is convenient to install and disassemble, and gets rid of the trouble that wiring is not easy near strong magnetism. In this way, a full phase detection of the hall element at the outer circumference of the cable is achieved. Different from the flexible TMR sensor array in the literature TMR sensor array-based wire breakage defect detection device and application research thereof, the invention adopts a linear arrangement mode, and the detection element adopts a Hall element.
And a Hall element (9) welded on the surface of the flat flexible board (10). Only one hall element (9) can be welded without affecting the detection accuracy. When improving and detect the precision, can weld a plurality of hall element (9), hall element is around the mode that the wire rope outer lane was evenly arranged promptly, can accomplish the detection to wire rope full phase place this moment. The arrangement quantity is determined by the diameter of the steel wire rope, and meanwhile, the quantity of the Hall elements (9) can be increased on the theoretical basis for higher detection precision.
The Hall element (9) welded on the flat cable flexible board (10) is arranged in parallel with the flat cable flexible board (10), and is arranged in a detection instrument together with the flat cable flexible board (10) for detecting the radial vector component in the magnetic flux leakage signal of the steel wire rope. When no damage exists on the steel wire rope, the numerical value of the radial vector of the magnetic leakage signal of the steel wire rope is zero, namely the initial magnetic field intensity of the detection input of the Hall element is zero, and the magnetic field intensity change can exist only when the damage exists. And detecting the radial vector component to obtain the health condition information of the steel wire rope.
Claims (10)
1. Steel wire rope detector with replaceable lining is characterized by comprising:
a plurality of mated inner and outer liner combinations:
a liner, the liner selected depending on the rope diameter of the steel rope detected, the difference between the liner and the liner being: the radius of the inner circular surface and the radius of the outer circular surface;
an outer liner, the selected outer liner depending on the outer circular radius of the selected inner liner, the difference between the outer liner and the outer liner being: radius of the inner circular surface;
the anti-collision pin is arranged between the inner lining and the outer lining, the shaft of the anti-collision pin is vertical to the shafts of the inner lining and the outer lining, and a processing hole is formed at the joint of the inner lining and the outer lining and is used as an installation space;
the flat cable soft board is arranged between the inner lining and the outer lining, and a processing and installing space is arranged on the inner circular surface of the outer lining.
2. The combination of mating inner and outer liners of claim 1 wherein:
in order to adapt to the detection of steel wire ropes with various rope diameters, a plurality of sets of inner liners and outer liners are combined.
3. The combination of multiple liners and an outer liner of claim 2 wherein:
the inner lining and the outer lining are in one-to-one correspondence, the radius of the inner circular surface of the outer lining is equal to the radius of the outer circular surface of the inner lining, and the inner circular surface and the outer circular surface are matched with each other.
4. The liner of claim 3, wherein:
ensuring the coaxiality of the steel wire rope in detection by using a lining type structure, wherein the diameter of the inner circular surface of the lining exceeds the diameter of the steel wire rope by 10-20 mm;
in order to ensure that the distance between the Hall element and the steel wire rope is as small as possible, the wall thickness of the lining is ensured to be 3-10 mm;
in order to ensure that the steel wire rope smoothly passes through, chamfering treatment is carried out on the end surface and the inner circular surface of the lining;
the difference between the inner liner and the inner liner is that: the radius of the inner circular surface and the radius of the outer circular surface;
two inner liners are arranged in one set of inner liner and outer liner combination.
5. The outer liner of claim 3, wherein:
in order to ensure the universality of the detection instrument, the radius of the inner circular surface of the outer lining is the same as that of the outer circular surface of the matched inner lining, and the radius of the outer circular surface of the outer lining is kept unchanged;
the difference between the outer liner and the outer liner is that: radius of the inner circular surface;
two outer linings are arranged in one set of inner lining and outer lining combination.
6. The anti-collision pin according to claim 1, characterized in that:
the anti-collision pin is arranged between the inner lining and the outer lining, and when the anti-collision pin works normally, the anti-collision pin and the inner lining are ensured not to slide;
when the diameter of the steel wire rope is too large and the steel wire rope cannot smoothly pass through the lining, the steel wire rope can break the anti-collision pin and drive the lining to move forwards, so that the steel wire rope is prevented from driving the whole instrument to move forwards;
the anti-collision pin is made of PVC material, the diameter is 3-4 mm, and the shearing strength is ensured to be 30-50 MPa;
two anti-collision pins are arranged in the combination of one set of inner lining and one set of outer lining.
7. The flexboard of claim 1, wherein:
welding Hall elements on the surface of the specially-made flat cable flexible board, and finishing the uniform arrangement of the Hall elements on the outer side of the steel wire rope in such a way;
the flat cable flexible board is arranged on the inner side of the outer liner, and a hole is bored in the middle of the inner circular surface of the outer liner to serve as an installation space of the flat cable flexible board; in order to ensure the normal installation of the flat cable flexible plate, the radial width of the boring hole is more than 5 mm.
8. The uniform arrangement of hall elements of claim 7, wherein:
one row of Hall elements are welded on the surface of the flat cable flexible board, and two rows of Hall elements can be welded to obtain richer steel wire rope condition information.
9. The flexboard of claim 7, wherein:
the flat cable soft board is in a straight shape when standing, is bent into a circular ring shape when being installed in an instrument, and is convenient to install.
10. The flexboard of claim 9, wherein:
because the flexible flat cable is extremely thin, the joint part of the flexible flat cable can extend to the outside of the instrument and is led out through the parting surface between the upper part and the lower part of the instrument;
it is also possible to make joint spaces for the outer lining, with the joints located inside the instrument.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113075286A (en) * | 2021-03-30 | 2021-07-06 | 中国矿业大学(北京) | Steel wire rope flaw detector with permanent magnet capable of moving axially |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113075286A (en) * | 2021-03-30 | 2021-07-06 | 中国矿业大学(北京) | Steel wire rope flaw detector with permanent magnet capable of moving axially |
| CN113075286B (en) * | 2021-03-30 | 2021-12-21 | 中国矿业大学(北京) | Steel wire rope flaw detector with permanent magnet capable of moving axially |
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| Publication number | Publication date |
|---|---|
| CN112378991B (en) | 2023-03-14 |
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