CN202794113U - Online real-time detection device of safety state of steel wire rope - Google Patents

Online real-time detection device of safety state of steel wire rope Download PDF

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Publication number
CN202794113U
CN202794113U CN 201220393724 CN201220393724U CN202794113U CN 202794113 U CN202794113 U CN 202794113U CN 201220393724 CN201220393724 CN 201220393724 CN 201220393724 U CN201220393724 U CN 201220393724U CN 202794113 U CN202794113 U CN 202794113U
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China
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wire rope
steel wire
signal
sensor
calibrate
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段权
李涌泉
谢旭梦
白文杰
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Xian Jiaotong University
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Xian Jiaotong University
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Abstract

The utility model discloses an online real-time detection device of the safety state of a steel wire rope. The online real-time detection device mainly comprises a sound emission detection system and an Internet-of-Things management platform. A damage signal of the steel wire rope is firstly collected through a sound emission sensor; then a sound emission signal is processed and analyzed, and a feature value of a wire breaking signal of the steel wire rope is extracted for judging the damage state and the safety level of the steel wire rope; the obtained signal is finally divided into two signals, one signal is used for directly performing interlocking protection on a steel wire rope operating system; and the other signal is transferred to a superior management department through an Internet of things for performing remote alarming and reminding and urging a related unit to perform inspection or maintenance on the steel wire rope. The technology can effectively improve the reliability in damage detection of the steel wire rope, simultaneously save the cost of regular inspection and also ensure the safe and stable operation of the steel wire rope.

Description

The online real-time detection apparatus of a kind of safe wire cable state
Technical field
The utility model relates to a kind of safe wire cable condition checkout gear, particularly the online real-time detection apparatus of a kind of safe wire cable state.
Background technology
There are the states such as the U.S., Britain, Germany, Japan, Canada, Poland in country early to Nondestructive Testing for Wire Ropes research, and has obtained certain achievement in practicality.
Wire rope Non-Destructive Testing the earliest can trace back to for 20 beginnings of the century.South African CE.Mc.cann and R.Colson have developed First wire rope electromagnetic nondestructive instrument jointly, are used for the cross section loss of measuring steel wire rope.This device adopts the interchange solenoid that wire rope is magnetized, when the wire rope cross section as inductor core changes, then the impedance between field coil and the magnetic test coil will change thereupon, the variation of the induction electromotive force in the record magnetic test coil just can be measured the fault that causes the wire rope changes of section in order.This method has adopted interchange (AC) excitation, so be called the AC method.Because kelvin effect, this method measuring accuracy is very poor, and the wire rope instrument generates heat easily, and each measurement all will be coil winding on wire rope, so be difficult to drop into practical application.
The magnetic flux leakage method that grows up the twenties is for detection of local damage, and excitation is to saturated vertically with wire rope owing to adopt direct current (DC), and the leakage magnetic flux of measurement injury region is judged degree of impairment, so be called the DC method.
1919, RLSanford and WB.Kouven-hoven have succeeded in developing in the world the cannot-harm-detection device of first employing magnetic flux leakage method principle, they are to two kinds of magnetic test coils, and namely a kind of single multiturn coil is got differential wave with another kind of two multiturn coils identical and close proximity.The antijamming capability of differential winding is strong, and the result who obtains is reliable, but since to spend a large amount of time coil winding on wire rope, so can't practical application.
Nineteen thirty-seven, R.Vmle and H.Mililer obtain the patent of T Split type differential coil, have solved this problem.Wbmle utilizes their invention at first to realize the online detection of wire rope subsequently.
Between after the sixties more than 20 year of twentieth century, the various countries scholar detects the problem that exists for wire rope and carries out extensive and deep research in principle and practice, obtained larger progress, thereby made the wire rope detection technique enter a new stage.The scholar of various countries has carried out comprehensive research to excitation unit, pick-up unit, the wire rope fault signature of wire rope, has obtained a series of achievements.Embody a concentrated expression of: excitation unit is used strong permanent magnet instead, and pick-up unit was both also used Hall element, fluxgate etc. with coil.Such as doctor's E.Kalwa primary study at Canadian mining industry energy technology center use the method that Hall subassembly detects wire rope leakage flux and main flux, by a large amount of experiments, analyse in depth the quantitative relationship of wire rope local fault and detection signal, found out some relations between partial fault quantitative characteristic and the detection signal.
Last century 60, various countries also successively released many wire rope testers to the eighties.The typical case has: the WBK series defectoscope of the HHCK series defectoscope of the M series of Poland and MD series defectoscope, the Soviet Union, the MRT type series defectoscope of Japan, Germany and the LMA series defectoscope of the U.S. etc.After the eighties, because the develop rapidly of electronic technology, semiconductor technology, computer technology and the present information treatment technologies such as pattern-recognition and artificial intelligence detects for the automatic ration of damage of steel cable, provide technical support, laid a good foundation.Especially aspect the research and development of the method for pattern-recognition, quantitative test and the processing of damage of steel cable detection signal and instrument, constantly release take the U.S. as some main advanced measuring techniques.The mid-90, the fast development of computer technology and integrated circuit has also brought the opportunity of development to steel rope flow detector.Nineteen ninety-five, Canada released the principle prototype E41 of computer based MagnograPhB shaped steel wire rope defectoscope on original detection principle basis, had stepped major step for eliminating the impact of human factor in wire rope detects.
China's Nondestructive Testing for Wire Ropes is started late, and has just begun research the beginning of the sixties.The steel rope flow detector of domestic self-developing development generally is the pick-up unit of single factors (mainly for fracture of wire).Professors Yang Shuzi of the Central China University of Science and Technology etc. have just begun the online research that detects of steel rope fault in the eighties, and research emphasis is the quantitative detection of fracture of wire.They also adopt magnetic flux leakage method, with permanent magnet to the wire rope excitation, with the field signal on all directions around the integrated hall element measuring steel wire rope, spacing with code-disc control sampling, with computing machine data are processed, and the magnetic excitation circuit of wire rope, signal processing etc. carried out large quantity research, and at first succeeded in developing MTC-94 shaped steel wire rope defectoscope, detect qualitatively the local anomaly fault of wire rope.At the end of the eighties, adopting again portable machine is that detection platform has been developed GDJY series steel rope fault instrument, 1992 the end of the year GDJY-B shaped steel wire rope fracture of wire instrument by technical appraisement, this instrument adopts " poly-magnetic " technology for detection stray field at flaw detection sensor, this is the breakthrough on the magnetic leakage detection detection technique.Owing to adopt computing machine to improve the intelligent level of instrument, realized the equidistant sampling of wire rope detection signal, effective exploration has been carried out in the quantitative identification of extraction, fracture of wire detection signal for the local flaw signal feature, realized the quantitative detection of fracture of wire, oneself is in the leading level in the world this technology, and in actual promoting the use, obtained preferably effect, for contribution has been made in the development of China's wire rope detection technique.
The end of the eighties, west, Luoyang, henan ravine mining and metallurgy electromechanical research has been succeeded in developing GXT type fracture of wire on-line measuring device, and this instrument mainly detects local damage, and the method that it adopts is very unique, do not belong to strictly speaking magnetic flux leakage method, as long as wire rope is just passable through DC excitation before detecting.The measuring sensor that it adopts is the dynamic inductive coil of developing voluntarily, and this instrument is more influential at home.The middle and later periods nineties, Shanghai Maritime University realizes that in the laboratory fluxgate detects wire rope fault stray field, and the wire rope fault detect research based on microcomputer and coil has been done by Fusun PetroleumCollege.These work are generally limited to laboratory study.In addition, the TCK damage of steel cable quantitative detection system that Luoyang TCK wire rope detection technique company limited develops is found what the technical foundation of " the Dou Shi high sensitive sensor " of " space magnetic field vector composition principle " and his invention was succeeded in developing professor Dou Yutang, adopting the weak magnetic detection technique of its original creation, is a quantum jump with respect to traditional strong magnetic detection technique.
Generally speaking, present single cross section magnetic flux evaluation method is fairly perfect, but the greatest problem of the method is and can only estimates the fracture of wire amount in the cross section, and the generation of actual fracture of wire is not often in a cross section, therefore the fatal problem of this series products is to fail to report, and the artificial abandoned tender criterion of declaring that proposes causes safety allowance excessive, wastes huge.
Because the develop rapidly of electronic technology, semiconductor technology, computer technology and the present information treatment technologies such as pattern-recognition and artificial intelligence provides technical support for the automatic ration detection of damage of steel cable.The main direction of at present the party's surface technology development is in pattern-recognition, quantitative test and the sensor of damage of steel cable detection signal and microminiaturization, long-range and the intelligent development of supervisory system.
The utility model is intended to the acoustic emission Dynamic Non-Destruction Measurement is introduced into the wire rope detection field, and the bond networking technology is set up intelligentized wire rope operation detection, fault diagnosis and a register system, by means of the effective management method of advanced person and technological means, constantly monitor the operation of wire rope, accurately reflect the wire rope running status, find early potential safety hazard, stopping as far as possible wire rope moves in spite of illness, constructed the safe wire cable monitoring network, strengthen standardized administration, guarantee 24 hours safe and reliable operations of wire rope.
The utility model content
For defective or deficiency that above-mentioned prior art exists, the purpose of this utility model is, provides a kind of safe wire cable state online real-time detection apparatus, realizes dynamic online real-time the detection.
For achieving the above object, the utility model is by the following technical solutions:
The online real-time detection apparatus of a kind of safe wire cable state, comprise acoustic emission detection system, the signal analysis and processing unit, the overhead control unit, and display alarm and braking and unit, described acoustic emission detection system is connected to detect the local flaw signal of wire rope with wire rope, described signal analysis and processing unit be input as the Broken Wires Signals of Wire Rope that acoustic emission detection system collects, be output as the safe class of wire rope, the output of described signal analysis and processing unit is divided into two-way, the elementary single-chip computer control system of leading up to links to each other with display alarm and brake unit, the Internet of Things of leading up in addition links to each other with the overhead control unit, the output of described overhead control unit links to each other with display alarm and brake unit, the output terminal of described display alarm and brake unit is connected with the wire rope controller, acts on wire rope.
As preferred embodiment of the present utility model, the multiple channel acousto transmitter that described acoustic emission detection system comprises calibrate AE sensor and links to each other with calibrate AE sensor, wherein, described calibrate AE sensor links to each other with wire rope to be detected;
As preferred embodiment of the present utility model, described wirerope-winding is on traction sheave, and described calibrate AE sensor is installed on the traction sheave wire rope is detected;
As preferred embodiment of the present utility model, described wirerope-winding is on traction sheave, and described calibrate AE sensor is installed on the wire rope;
As preferred embodiment of the present utility model, described wirerope-winding is on traction sheave, and described calibrate AE sensor is connected with wire rope by the waveguide rod that is installed on the wire rope.
Compared with prior art, the utility model device has the following advantages at least: the utility model gathers by the local flaw signal of acoustic emission detection system to wire rope, by the signal analysis and processing unit this local flaw signal is analyzed and processed, thereby obtain the safe class of wire rope, at last this safe class is uploaded to the overhead control unit, and the processing of reporting to the police.The measurement result of the utility model device is more accurate, and simple in structure, and is easy to operate.
Description of drawings
Fig. 1 is the one-piece construction synoptic diagram of the utility model device;
Fig. 2 is the structural representation of the utility model measurement device system.
Among Fig. 2,5 rotating shafts of 1 bearing, 2 calibrate AE sensors, 3 wire rope, 4 traction sheaves.
Embodiment
Be described in detail below in conjunction with accompanying drawing and a kind of embodiment of the present utility model:
The online real-time detection apparatus of a kind of safe wire cable state, comprise acoustic emission detection system, the signal analysis and processing unit, the overhead control unit, and display alarm braking and unit, described acoustic emission detection system is connected to detect the local flaw signal of wire rope with wire rope, described signal analysis and processing unit be input as the Broken Wires Signals of Wire Rope that acoustic emission detection system collects, be output as the safe class of wire rope, the output of described signal analysis and processing unit is divided into two-way, the elementary single-chip computer control system of leading up to links to each other with display alarm and brake unit, the Internet of Things of leading up in addition links to each other with the overhead control unit, the output of described overhead control unit links to each other with display alarm braking and unit, the output terminal of described display alarm braking and unit is connected with the wire rope controller, acts on wire rope.
The multiple channel acousto transmitter that described acoustic emission detection system comprises calibrate AE sensor and links to each other with calibrate AE sensor, wherein, described calibrate AE sensor links to each other with wire rope to be detected; Described wirerope-winding is on traction sheave, and described calibrate AE sensor is installed on the traction sheave wire rope is carried out.
The online real-time detection apparatus of the utility model safe wire cable state mainly is comprised of three parts: acoustic emission detection system, signal analysis and processing system, controlling alarm unit.Acoustic emission detection system comprises calibrate AE sensor and the hyperchannel hair tonic jet device that is connected with calibrate AE sensor, and described calibrate AE sensor links to each other with wire rope to be detected, in order to gather the local flaw signal of wire rope; Described signal analysis and processing system extracts and processes to obtain the safe class of wire rope to the local flaw signal of calibrate AE sensor collection, then the signal after will processing is divided into two, and one road signal directly carries out interlock protection by elementary single-chip computer control system to the wire rope operational system; Another road signal arrives the overhead control unit by Internet of Things with damage of steel cable information effective communication, carries out remote alarms, and reminds and supervise relevant unit to carry out inspection or the maintenance of wire rope.
Described acoustic emission detection system mainly is comprised of calibrate AE sensor and multiple channel acousto transmitter; Principle of work is: the damage signal of wire rope is delivered to above the traction sheave, and receive damage signal by the calibrate AE sensor that is installed in above the traction sheave this moment, thereby realizes the real-time online of wire rope is detected.
What deserves to be explained is, as a kind of embodiment of the present utility model, described calibrate AE sensor is installed in traction sheave, wirerope-winding is on traction sheave, yet, be connected with wire rope if calibrate AE sensor is directly installed on the wire rope or by miscellaneous part (for example waveguide rod), also can realize the object of the invention.
Described signal analysis and processing system carries out analyzing and processing to the signal that obtains, and obtains the local flaw signal of wire rope, and judges thus operation conditions and the safe class of wire rope.
The utility model purpose is to adopt new pick-up unit---and the acoustic emission Dynamic Non-Destruction Measurement detects and estimates the safe wire cable state, and the bond networking technology is realized effective monitoring and management to the wire rope operation.At first by calibrate AE sensor the fracture of wire damage signal of wire rope is carried out comprehensive perception and detection; Again acoustic emission signal effectively is transferred to the multiple channel acousto transmitter, through to after the signal analysis and processing, extract the damage characteristic parameter, judge faulted condition and the safe class of wire rope, produce one road signal direct effect wire rope operational system, play the intelligent emergency protective effect; Another road signal then is delivered to the overhead control unit by technology of Internet of things; carry out remote alarms and protection; upper management department personnel determine wire rope security of operation grade according to the damage of steel cable state again, realize Intelligent Measurement and management to the running status of wire rope.This technology has improved the reliability that damage of steel cable detects effectively, has saved simultaneously the expense of making regular check on, and has also guaranteed the safe and stable operation of wire rope.
Composition of the present utility model and connected mode (with reference to the accompanying drawings):
1, acoustic emission detection system: mainly by calibrate AE sensor, the multiple channel acousto transmitter forms;
2, signal analysis and processing system: Acoustic emission signal processing, demonstration, analytical equipment form;
3, connected mode: at first by calibrate AE sensor the damage of steel cable signal is gathered; Then acoustic emission signal is processed and analyzed, extract the Broken Wires Signals of Wire Rope eigenwert, in order to faulted condition and the safe class of weighing wire rope; At last the gained signal is divided into two, one road signal directly carries out interlock protection to the wire rope operational system; Another road signal is delivered to upper management department by Internet of Things, carries out remote alarms, and reminds and supervise relevant unit to carry out inspection or the maintenance of wire rope.
Innovative point of the present utility model and technology path:
1, utilizes acoustic emission to detect online fracture of wire, can include the fracture of wire of varying cross-section in scope of statistics, than traditional single xsect method scientific and effective more;
2, set up operation conditions and the safe class evaluation system of wire rope, can distant early warning by the Internet of Things management platform, detection sensitivity is high, and resolution characteristic is strong;
3, acoustic emission is responsive to dynamic defect, can immediately find in defective germinating and expansion process, and signal is had the effect that adds up, and the energy real-time online detects the ruuning situation of wire rope;
4, can accurately determine position and measuring steel wire rope fracture of wire degree and the number that defective occurs by wave form analysis.
The utility model can reasonably be estimated disconnected rope form attitude more comprehensively, stops to fail to report, report by mistake phenomenon, the safe operation of the equipment such as the elevator of raising wire rope gearing, hanging ladder, travelling belt, and social benefit is obvious; Simultaneously, product is after the equipment promotions such as elevator that belong to the special equipment supervision use, only calculate by the present 300 ten thousand years visitor of China elevator recoverable amount transformation scale, about 9,000,000,000 Renminbi of profit scale, can provide the wire rope utilization factor in addition, reduce unreasonable scrappage, save steel about 15%, have huge economic benefit and market potential; This project development has China's independent intellectual property rights, also will improve the technology content of elevator industry home products.
China's Statistical shows, if the instrument of the science of employing detects, scraps in good time, the annual consumption 12%-20% that can save at least wire rope, the 20%-30% of saving import wire rope foreign exchange.Simultaneously, day by day improve according to safety requirements such as the elevator of special equipment supervision, cableways, only according to conservative estimation of passenger elevator, China has now about 3,000,000 of labour passenger elevator, newly-increased passenger elevator was about 330,000 in 2011, and increase according to the annual growth of 30-40%, after the operational reliability of these elevators is included the security monitoring index request in and transformed, have sizable market potential.All elevator monitoring systems that use are at present not yet seen the report that similar products use.
The installation of sensor as shown in Figure 2 in the acoustic emission detection system: wherein, 1 is bearing, and 2 is calibrate AE sensor, and 3 is wire rope, and 4 is traction sheave, and 5 are rotating shaft.The damage signal that wire rope 3 produces in operational process is delivered to above the traction sheave 4, and receive damage signal by the calibrate AE sensor 2 that is installed in above the traction sheave this moment, thereby realizes the real-time online of wire rope is detected.The signal that sensor obtains effectively is transferred to the Analysis of Acoustic Emission Signal disposal system, and then running status and the safe class of wire rope are estimated.
The above only is a kind of embodiment of the present utility model, it or not whole or unique embodiment, the conversion of any equivalence that those of ordinary skills take technical solutions of the utility model by reading the utility model instructions is claim of the present utility model and contains.

Claims (5)

1. online real-time detection apparatus of safe wire cable state, it is characterized in that: comprise acoustic emission detection system, the signal analysis and processing unit, the overhead control unit, and display alarm braking and unit, described acoustic emission detection system is connected to detect the local flaw signal of wire rope with wire rope, described signal analysis and processing unit be input as the Broken Wires Signals of Wire Rope that acoustic emission detection system collects, be output as the safe class of wire rope, the output of described signal analysis and processing unit is divided into two-way, the elementary single-chip computer control system of leading up to links to each other with display alarm and brake unit, the Internet of Things of leading up in addition links to each other with the overhead control unit, the output of described overhead control unit links to each other with display alarm braking and unit, the output terminal of described display alarm braking and unit is connected with the wire rope controller, acts on wire rope.
2. the online real-time detection apparatus of safe wire cable state according to claim 1, it is characterized in that: the multiple channel acousto transmitter that described acoustic emission detection system comprises calibrate AE sensor and links to each other with calibrate AE sensor, wherein, described calibrate AE sensor links to each other with wire rope to be detected.
3. the online real-time detection apparatus of safe wire cable state according to claim 2, it is characterized in that: described wirerope-winding is on traction sheave, and described calibrate AE sensor is installed on the traction sheave wire rope is detected.
4. the online real-time detection apparatus of safe wire cable state according to claim 2, it is characterized in that: described wirerope-winding is on traction sheave, and described calibrate AE sensor is installed on the wire rope.
5. the online real-time detection apparatus of safe wire cable state according to claim 2, it is characterized in that: described wirerope-winding is on traction sheave, and described calibrate AE sensor is connected with wire rope by the waveguide rod that is installed on the wire rope.
CN 201220393724 2012-08-09 2012-08-09 Online real-time detection device of safety state of steel wire rope Expired - Fee Related CN202794113U (en)

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104965055A (en) * 2015-06-04 2015-10-07 中国矿业大学(北京) On-line detection and safety assessment method and system for mining steel wire rope
CN106395557A (en) * 2016-06-20 2017-02-15 南通三洋电梯有限责任公司 Elevator dray machine steel wire rope state online detection system and detection method thereof
CN108445084A (en) * 2018-02-09 2018-08-24 深圳市市政设计研究院有限公司 A kind of fracture of wire monitoring method and system based on drag-line or sunpender
CN108981891A (en) * 2018-09-20 2018-12-11 清诚声发射研究(广州)有限公司 Wire Rope Wire Break Detecting System and method
CN111521687A (en) * 2020-05-09 2020-08-11 山东大学 Inhaul cable broken wire distinguishing method and system based on acoustic emission signal analysis
RU2767280C1 (en) * 2021-05-04 2022-03-17 Федеральное государственное бюджетное учреждение науки Институт океанологии им. П.П. Ширшова РАН Method for determining dangerous places of breakage of metal cables and nylon halyards, and a device for preventing accidents during descent and lifting operations

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN104965055A (en) * 2015-06-04 2015-10-07 中国矿业大学(北京) On-line detection and safety assessment method and system for mining steel wire rope
CN106395557A (en) * 2016-06-20 2017-02-15 南通三洋电梯有限责任公司 Elevator dray machine steel wire rope state online detection system and detection method thereof
CN108445084A (en) * 2018-02-09 2018-08-24 深圳市市政设计研究院有限公司 A kind of fracture of wire monitoring method and system based on drag-line or sunpender
CN108981891A (en) * 2018-09-20 2018-12-11 清诚声发射研究(广州)有限公司 Wire Rope Wire Break Detecting System and method
CN108981891B (en) * 2018-09-20 2024-04-26 清诚声发射研究(广州)有限公司 Wire breakage detection system and method for steel wire rope
CN111521687A (en) * 2020-05-09 2020-08-11 山东大学 Inhaul cable broken wire distinguishing method and system based on acoustic emission signal analysis
CN111521687B (en) * 2020-05-09 2021-09-28 山东大学 Inhaul cable broken wire distinguishing method and system based on acoustic emission signal analysis
RU2767280C1 (en) * 2021-05-04 2022-03-17 Федеральное государственное бюджетное учреждение науки Институт океанологии им. П.П. Ширшова РАН Method for determining dangerous places of breakage of metal cables and nylon halyards, and a device for preventing accidents during descent and lifting operations

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