CN117665089A - Wire rope damage detection sensor and detection method based on split type PCB coil - Google Patents
Wire rope damage detection sensor and detection method based on split type PCB coil Download PDFInfo
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- CN117665089A CN117665089A CN202311629979.4A CN202311629979A CN117665089A CN 117665089 A CN117665089 A CN 117665089A CN 202311629979 A CN202311629979 A CN 202311629979A CN 117665089 A CN117665089 A CN 117665089A
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- 230000006378 damage Effects 0.000 title claims abstract description 74
- 238000001514 detection method Methods 0.000 title claims abstract description 64
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- 239000002184 metal Substances 0.000 claims abstract description 8
- 229910052751 metal Inorganic materials 0.000 claims abstract description 8
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- 230000010354 integration Effects 0.000 claims description 9
- 229910052802 copper Inorganic materials 0.000 claims description 8
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- 238000009659 non-destructive testing Methods 0.000 description 4
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- 208000027418 Wounds and injury Diseases 0.000 description 2
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- 230000009286 beneficial effect Effects 0.000 description 2
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Abstract
The invention discloses a split type steel wire rope damage quantitative detection sensor based on a PCB (printed circuit board), which comprises the steps of firstly simulating different design parameters of split type PCB coils by using magnetic field simulation software, and obtaining optimal design parameters according to simulation signals acquired by the coils; because the metal cross-sectional area loss rate of the steel wire rope is in direct proportion to the magnetic flux variation signal, an integrator is added into the PCB coil to obtain the magnetic flux variation signal; and finally, acquiring a magnetic flux variation signal of the steel wire rope by using a split type PCB coil detection sensor, obtaining a damage signal of the steel wire rope after filtering treatment, and fitting a damage quantitative relation to realize quantitative analysis of the damage degree of the steel wire rope.
Description
Technical Field
The invention belongs to the technical field of nondestructive testing of steel wire ropes, and particularly relates to a design and a detection method of a steel wire rope damage detection sensor based on a split type PCB coil.
Background
The steel wire rope is mostly applied to hoisting or traction places of large-scale equipment, so that huge potential safety hazards and property loss can be brought about by failure of the steel wire rope. In the use process, the steel wire rope can generate different forms of damage due to the complexity of the steel wire rope structure and the diversity of application environments, so that nondestructive detection of the steel wire rope is faced with a plurality of difficulties. The damage of the steel wire rope can be classified into a Local defect (LF) and a cross-section loss (Loss of Metallic Area LMA) according to the nature and the characteristics of the damage of the steel wire rope. The LF type mainly comprises wire breakage, pitting, local shape change and the like of a steel wire rope, and the LMA type mainly comprises abrasion, corrosion, wire rope diameter reduction and other damages.
In recent years, aiming at nondestructive testing of steel wire ropes, different testing techniques are gradually perfected. According to different detection principles, the detection methods which are widely used at present are an image method, an acoustic emission method, an electromagnetic detection method and the like. Because the magnetic permeability of the steel wire rope material is good and the electromagnetic signal penetrability is high, the electromagnetic detection method based on the magnetic signal achieves good detection effect. Relevant standards are established for electromagnetic nondestructive testing of ferromagnetic steel wire ropes in China, and the detection method is marked to be gradually standardized and widely applied to actual industry.
In nondestructive testing of steel wire ropes, the Hall element array is generally adopted for testing LF type damage, the coil sensor is generally adopted for testing LMA type damage, the coil sensor is divided into a main magnetic flux detection coil and a leakage magnetic flux detection coil, the signal to noise ratio of detection signals of the main magnetic flux detection coil is far higher than that of the leakage magnetic flux detection coil, and the two ends of the steel wire ropes are fixed in actual operation and cannot be easily taken down, so that the traditional main magnetic flux detection coil cannot be applied to actual testing, and therefore, the split main magnetic flux detection coil is designed to realize the detection of the LMA type damage of the steel wire ropes. In addition, a sensor does not exist, so that the LF type damage and the LMA type damage can be detected, no good quantitative method exists for the LF type damage or the LMA type damage at present, only qualitative detection is remained, and therefore, the design of the sensor which can realize detection and quantification for the LF type damage and the LMA type damage has important engineering significance for nondestructive detection of a steel wire rope.
Disclosure of Invention
The invention aims to overcome the defects of the existing detection sensor, provides a design and a detection method of a steel wire rope damage detection sensor based on a split type PCB coil, designs a split type PCB coil to replace a traditional main magnetic flux detection coil, optimizes a detection structure, provides a detection analysis method, and is beneficial to improving the detection efficiency of steel wire rope damage.
In order to achieve the aim of the invention, the split type steel wire rope damage quantitative detection sensor based on the PCB is characterized by comprising the following components: the device comprises a split type PCB coil, an excitation structure, a framework and a data acquisition card;
the split type PCB coil consists of an upper semicircular printed circuit board and a lower semicircular printed circuit board, wherein the inner diameter and the outer diameter of each semicircular printed circuit board are respectively R 1 And R is 2 The number of layers is k, n semicircular printed copper wires with the radius of R=r, R=r+d, R=r+2d, … and R=r+ (n-1) d) are distributed from inside to outside in each layer, the line width of each copper wire is z, the thickness is h, and R is equal to the thickness of each copper wire>R 1 ，R<R 2 ；
The printed circuit board is positioned at the axial middle part of the sensor, clamped by the framework structure and arranged below the excitation structure, and connected with the upper and lower semi-annular printed circuit boards through FPC flexible flat cables; in addition, an integration circuit is arranged on the outermost layer of the upper semicircular printed circuit board and used for eliminating the influence of the detection speed on the signal amplitude;
each group of excitation structure consists of a pair of magnets and armatures, and m groups are totally more than or equal to 1; the device is used for saturating the magnetized steel wire rope to enable the damaged part to generate a leakage magnetic field, and the excitation structure and the data acquisition card are fixed on the framework through screws;
the whole structure of the framework is hollow cylindrical, the excitation structure and the data acquisition card are fixed on the outer side of the framework through screws, and the split type PCB coil card is arranged on the inner side of the framework and right below the armature and vertical to the direction of the armature;
the acquisition card is used for acquiring the integrated voltage signal, performing analog-to-digital conversion and uploading the integrated voltage signal to the host.
In addition, the invention also provides a detection method of the steel wire rope damage detection sensor based on the split type PCB coil, which is characterized by comprising the following steps:
(1) The sensor is arranged on the steel wire rope to be tested, and the excitation structure can effectively magnetize the steel wire rope through relative movement between the sensor and the steel wire rope, and when the steel wire rope is damaged, the split type PCB coil can detect induction voltage U with magnetic flux change i The integrating circuit senses the voltage U i Output voltage signal U after integration o The acquisition card acquires a voltage signal U o Performing analog-to-digital conversion to obtain a signal S (T), wherein t=1, 2, …, T and T are the total sampling point number;
(2) The acquisition card transmits the signal S (t) to the host, and an output signal Y (t) is obtained through a digital processing method of a median filter and a Hanning filter carried by the host;
(3) Calculating the average value of the voltages of Y (t), marking the average value as A, and taking the A as a threshold value; finding out the position of the voltage value higher than A in Y (t), recording the position points as the damaged positions of the steel wire rope, wherein the amplitude change of the damaged positions is delta U (d), d=1, 2, …, m and m are the total number of the damaged positions of the steel wire rope;
(4) Substituting the amplitude change of each damage position into the following fitting function to obtain the metal cross-sectional area loss rate of each damage position:
wherein loss (d) is the sectional area loss rate of the d-th damage of the steel wire rope, b is the intercept of the fitting function, and a is the slope coefficient of the fitting function;
(5) Judging the damage condition of the steel wire rope;
if the number m of the damaged positions of the steel wire rope to be detected is larger than a threshold value or the metal cross-sectional area loss rate of a certain damaged position is larger than a specified threshold value, judging that the steel wire rope is scrapped.
The invention aims at realizing the following steps:
the invention relates to a split type steel wire rope damage quantitative detection sensor based on a PCB (printed circuit board), which comprises the steps of firstly simulating different design parameters of split type PCB coils by using magnetic field simulation software, and obtaining optimal design parameters according to simulation signals acquired by the coils; because the metal cross-sectional area loss rate of the steel wire rope is in direct proportion to the magnetic flux variation signal, an integrator is added into the PCB coil to obtain the magnetic flux variation signal; and finally, acquiring a magnetic flux variation signal of the steel wire rope by using a split type PCB coil detection sensor, obtaining a damage signal of the steel wire rope after filtering treatment, and fitting a damage quantitative relation to realize quantitative analysis of the damage degree of the steel wire rope.
Meanwhile, the steel wire rope damage detection sensor and the detection method based on the split type PCB coil have the following beneficial effects:
1. according to the invention, the PCB coil structure is split, so that inconvenience in coil installation caused by irremovable two ends in the steel wire rope detection process is avoided, the traditional coil installation mode is avoided, and the detection efficiency can be effectively improved;
2. the sensor can detect LF damage such as broken wires and LMA damage such as abrasion simultaneously, the application range of the sensor is expanded, and compared with the existing magnetic flux leakage detection mode based on the Hall sensor in the market, the sensor has stronger detection capability and wider application range;
3. the magnetic flux variation signal acquired by the method has higher signal-to-noise ratio, a complex signal processing method is not needed, the damage degree can be effectively and quantitatively judged based on fitting data of the sample rope, and a reference is provided for quantitative analysis of the damage of the steel wire rope.
Drawings
Fig. 1 is a schematic diagram of a wire rope damage detection sensor based on a split type PCB coil;
FIG. 2 is a schematic diagram of an integrator circuit based on a split PCB coil;
FIG. 3 is a physical diagram of a split PCB coil;
fig. 4 is a schematic diagram of a wire rope damage detection sensor based on a split PCB coil;
fig. 5 is a steel wire rope LF-type damage real object diagram;
FIG. 6 is an LF class injury detection result;
FIG. 7 shows LMA type injury detection results.
Detailed Description
The following description of the embodiments of the invention is presented in conjunction with the accompanying drawings to provide a better understanding of the invention to those skilled in the art. It is to be expressly noted that in the description below, detailed descriptions of known functions and designs are omitted here as perhaps obscuring the present invention.
Examples
In this embodiment, as shown in fig. 1, the wire rope damage detection sensor based on the split PCB coil of the present invention includes: the device comprises a split type PCB coil 1, an excitation structure 2, a framework 3 and a data acquisition card 4;
the split type PCB coil consists of an upper semi-annular printed circuit board and a lower semi-annular printed circuit board, wherein the inner diameter and the outer diameter of each semi-annular printed circuit board are respectively R 1 And R is 2 The number of layers is k, n semicircular printed copper wires with the radius of R=r, R=r+d, R=r+2d, … and R=r+ (n-1) d) are distributed from inside to outside in each layer, the line width of each copper wire is z, the thickness is h, and R is equal to the thickness of each copper wire>R 1 ，R<R 2 ；
The printed circuit board is positioned at the axial middle part of the sensor, clamped by the framework structure and arranged below the excitation structure, and connected with the upper and lower semi-annular printed circuit boards through FPC flexible flat cables; in addition, an integration circuit is arranged on the outermost layer of the upper semicircular printed circuit board and used for eliminating the influence of the detection speed on the signal amplitude;
in this embodiment, since the magnetic flux variation is affected by the speed, in order to eliminate the influence of the speed on the signal amplitude, the present invention designs an integrating circuit as shown in FIG. 2, which includes a capacitor C 1 Resistance R 1 /R 2 An operational amplifier, a linear voltage regulator and a bidirectional voltage converter;
inductive voltage U for detecting magnetic flux change caused by steel wire rope damage by split type PCB coil i The linear voltage stabilizer induces a voltage U i Reduced to 2.5V and used for power supply positive input of operational amplifier, while bidirectional voltage converter inverts 2.5V voltage to-2.5V voltage supply operationA negative input of the amplifier; then by resistance R 1 And capacitor C 1 After forming an RC filter circuit for filtering, the filter is formed by a resistor R 2 Is responsible for controlling the amplification factor after integration, so that the operational amplifier outputs an integrated voltage signal U o 。
The number of coil layers k, the number of copper wires n, the radius r of the copper wires, the line distance d, the line width z and the thickness h of the split PCB coil are all analyzed by magnetic field simulation software and the optimal values are obtained, in the embodiment, the number of coil layers k=4 and n=40 turns of coil structure, wherein the line width z=0.15 mm, r=22 mm, d=0.176 mm and the copper thickness h=0.035 mm. A physical diagram of the thus constructed complete split PCB coil is shown in fig. 3.
As shown in FIG. 4, each group of the excitation structure is composed of a pair of magnets (21) and armatures (22), m groups are total, m is larger than or equal to 1, and 3 groups are total in the embodiment; the excitation structure is used for saturating and magnetizing the steel wire rope, so that a leakage magnetic field is generated at the damaged part;
in this embodiment, as shown in fig. 4, the overall structure of the skeleton is hollow cylindrical, the excitation structure and the data acquisition card are fixed on the outer side of the skeleton by screws, and the split PCB coil card is positioned on the inner side of the skeleton and just below the armature and perpendicular to the armature direction;
the acquisition card is connected with the output end of the integration circuit and is used for acquiring the integrated voltage signal, performing analog-to-digital conversion and uploading the integrated voltage signal to the host.
In the embodiment, after the steel wire rope is saturated and magnetized, the sensor analyzes the damage condition of the steel wire rope by collecting the magnetic flux variation in the split type PCB coil.
The following describes a method for detecting damage to a steel wire rope damage detection sensor based on a split type PCB coil in detail, and the method comprises the following steps:
(1) The sensor is arranged on the steel wire rope to be tested, and the excitation structure can effectively magnetize the steel wire rope through relative movement between the sensor and the steel wire rope, and when the steel wire rope is damaged, the split type PCB coil can detect induction voltage U with magnetic flux change i The integrating circuit senses the voltage U i Output voltage signal U after integration o The acquisition card acquires a voltage signal U o Performing analog-to-digital conversion to obtain a signal S (T), wherein t=1, 2, …, T and T are the total sampling point number;
(2) The acquisition card transmits the signal S (t) to the host, and an output signal Y (t) is obtained through a digital processing method of a median filter and a Hanning filter carried by the host;
(3) Calculating the average value of the voltages of Y (t), marking the average value as A, and taking the A as a threshold value; finding out the position of the voltage value higher than A in Y (t), recording the position points as the damaged positions of the steel wire rope, wherein the amplitude change of the damaged positions is delta U (d), d=1, 2, …, m and m are the total number of the damaged positions of the steel wire rope;
(4) Substituting the amplitude change of each damage position into the following fitting function to obtain the metal cross-sectional area loss rate of each damage position:
wherein loss (d) is the sectional area loss rate of the d-th damage of the steel wire rope, b is the intercept of the fitting function, and a is the slope coefficient of the fitting function;
(5) Judging the damage condition of the steel wire rope;
if the number m of the damaged positions of the steel wire rope to be detected is larger than a specified threshold value or the metal cross-sectional area loss rate of a certain damaged position is larger than the specified threshold value, judging that the steel wire rope is scrapped.
In this embodiment, the sensor detects the sample rope, and the sample rope contains the damage of 4 positions shown in fig. 5, namely 1,2 and 3 broken wires, corresponding to (a) to (d) in fig. 5, and the detection result of the detection of the damage of the steel wire rope is shown in fig. 6, wherein the signal amplitude change ratio corresponds to the damage degree, and the detection effect of the sensor on the LF type damage is verified. Because LMA type damage is difficult to quantitatively manufacture, according to the specification of GB/T21837-2008 electromagnetic detection method for ferromagnetic steel wire ropes, the nondestructive detection method for the steel wire ropes can adopt a large column formed by jointly splicing a plurality of steel wires with small inner diameters to simulate the LMA type damage of the steel wire ropes, and FIG. 7 is an LMA type damage signal obtained by the sectional area loss rate of 3.94%, the signal-to-noise ratio of the damage signal is extremely high, the amplitude change of the damage signal can be easily distinguished, and the detection performance of the invention in the LMA type damage is verified.
While the foregoing describes illustrative embodiments of the present invention to facilitate an understanding of the present invention by those skilled in the art, it should be understood that the present invention is not limited to the scope of the embodiments, but is to be construed as protected by the accompanying claims insofar as various changes are within the spirit and scope of the present invention as defined and defined by the appended claims.
Claims (4)
1. Wire rope damage detection sensor based on split type PCB coil, its characterized in that includes: the device comprises a split type PCB coil, an excitation structure, a framework and a data acquisition card;
the split type PCB coil consists of an upper semicircular printed circuit board and a lower semicircular printed circuit board, wherein the inner diameter and the outer diameter of each semicircular printed circuit board are respectively R 1 And R is 2 The number of layers is k, n semicircular printed copper wires with the radius of R=r, R=r+d, R=r+2d, … and R=r+ (n-1) d) are distributed from inside to outside in each layer, the line width of each copper wire is z, the thickness is h, and R is equal to the thickness of each copper wire>R 1 ，R<R 2 ；
The printed circuit board is positioned at the axial middle part of the sensor, clamped by the framework structure and arranged below the excitation structure, and connected with the upper and lower semi-annular printed circuit boards through FPC flexible flat cables; in addition, an integration circuit is arranged on the outermost layer of the upper semicircular printed circuit board and used for eliminating the influence of the detection speed on the signal amplitude;
each group of excitation structure consists of a pair of magnets and armatures, and m groups are totally more than or equal to 1; the device is used for saturating the magnetized steel wire rope to enable the damaged part to generate a leakage magnetic field, and the excitation structure and the data acquisition card are fixed on the framework through screws;
the whole structure of the framework is hollow cylindrical, the excitation structure and the data acquisition card are fixed on the outer side of the framework through screws, and the split type PCB coil card is arranged on the inner side of the framework and right below the armature and vertical to the direction of the armature;
the acquisition card is used for acquiring the integrated voltage signal, performing analog-to-digital conversion and uploading the integrated voltage signal to the host.
2. The split type PCB coil-based steel wire rope damage detection sensor according to claim 1, wherein the number k of coil layers, the number n of copper wires, the radius R and R of copper wires, the line width z and the thickness h of the split type PCB coil are all analyzed by magnetic field simulation software, and the optimal values of the split type PCB coil are obtained.
3. The split PCB coil based wire rope damage detection sensor of claim 1, wherein the integrating circuit comprises a capacitor C 1 Resistance R 1 /R 2 An operational amplifier, a linear voltage regulator and a bidirectional voltage converter;
inductive voltage U for detecting magnetic flux change caused by steel wire rope damage by split type PCB coil i The linear voltage stabilizer induces a voltage U i The voltage is reduced to 2.5V and is used for the positive electrode input of a power supply of the operational amplifier, and meanwhile, the bidirectional voltage converter inverts the voltage of 2.5V into the voltage of-2.5V and supplies the voltage to the negative electrode input of the operational amplifier; then by resistance R 1 And capacitor C 1 After forming an RC filter circuit for filtering, the filter is formed by a resistor R 2 Is responsible for controlling the amplification factor after integration, so that the operational amplifier outputs an integrated voltage signal U o 。
4. The damage detection method of the steel wire rope damage detection sensor based on the split type PCB coil is characterized by comprising the following steps of:
(1) The sensor is arranged on the steel wire rope to be tested, and the excitation structure can effectively magnetize the steel wire rope through relative movement between the sensor and the steel wire rope, and when the steel wire rope is damaged, the split type PCB coil can detect induction voltage U with magnetic flux change i The integrating circuit senses the voltage U i Output voltage signal U after integration o Acquisition cardVoltage collecting signal U o Performing analog-to-digital conversion to obtain a signal S (T), wherein t=1, 2, …, T and T are the total sampling point number;
(2) The acquisition card transmits the signal S (t) to the host, and an output signal Y (t) is obtained through a digital processing method of a median filter and a Hanning filter carried by the host;
(3) Calculating the average value of the voltages of Y (t), marking the average value as A, and taking the A as a threshold value; finding out the position of the voltage value higher than A in Y (t), recording the position points as damage positions of the steel wire rope, wherein the peak value of the damage positions is DeltaU (d), d=1, 2, …, m and m are the total number of the damage positions of the steel wire rope;
(4) Substituting the peak value of each damage position into the following fitting function to obtain the metal cross-sectional area loss rate of each damage position:
wherein loss (d) is the sectional area loss rate of the d-th damage of the steel wire rope, b is the intercept of the fitting function, and a is the slope coefficient of the fitting function;
(5) Judging the damage condition of the steel wire rope;
if the number m of the damaged positions of the steel wire rope to be detected is larger than a specified threshold value or the metal cross-sectional area loss rate of a certain damaged position is larger than the specified threshold value, judging that the steel wire rope is scrapped.
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| CN202311629979.4A CN117665089A (en) | 2023-11-30 | 2023-11-30 | Wire rope damage detection sensor and detection method based on split type PCB coil |
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| CN202311629979.4A CN117665089A (en) | 2023-11-30 | 2023-11-30 | Wire rope damage detection sensor and detection method based on split type PCB coil |
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