WO2016119331A1 - 腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统 - Google Patents

腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统 Download PDF

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Publication number
WO2016119331A1
WO2016119331A1 PCT/CN2015/078720 CN2015078720W WO2016119331A1 WO 2016119331 A1 WO2016119331 A1 WO 2016119331A1 CN 2015078720 W CN2015078720 W CN 2015078720W WO 2016119331 A1 WO2016119331 A1 WO 2016119331A1
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Prior art keywords
wire rope
wheel
corrosion
bending fatigue
proximity switch
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Ceased
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PCT/CN2015/078720
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English (en)
French (fr)
Inventor
王大刚
李晓五
王琳琳
朱真才
张德坤
茅献彪
彭玉兴
葛世荣
王庆良
刘洪涛
罗勇
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China University of Mining and Technology CUMT
China University of Mining and Technology Beijing CUMTB
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China University of Mining and Technology CUMT
China University of Mining and Technology Beijing CUMTB
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Priority to RU2016143560A priority Critical patent/RU2649036C2/ru
Publication of WO2016119331A1 publication Critical patent/WO2016119331A1/zh
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/32—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces
    • G01N3/38—Investigating strength properties of solid materials by application of mechanical stress by applying repeated or pulsating forces generated by electromagnetic means
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N17/00—Investigating resistance of materials to the weather, to corrosion, or to light
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
    • G01N3/20—Investigating strength properties of solid materials by application of mechanical stress by applying steady bending forces

Definitions

  • the invention relates to a monitoring system, in particular to a steel wire rope bending fatigue damage monitoring system under the action of corrosion-alternating load coupling.
  • the wire rope is a space spiral structure in which a plurality of steel wires are twisted into strands and then twisted into strands.
  • the advantages of good bearing capacity, good bending flexibility, smooth motion, no noise, large safety factor and light weight are widely used in each.
  • Lifting and lifting systems In the mine hoisting system, the hoisting wire rope connection mine hoist and lifting container together constitute the mine hoisting system, which is responsible for the task of upgrading coal, vermiculite, decentralized materials, lifting personnel and equipment. Once the wire rope fails to break, it will lead to the death of the well. Major accidents, and seriously affect the normal production of mines and the safety of personnel.
  • the mine hoisting rope is in the working environment of friction, humidity and corrosion for a long time (pH is about 6-12), it is subject to repeated tensile and bending loads; during the process of mine lifting, due to the acceleration or deceleration of the hoist The process and the time-varying overhanging rope length allow the hoisting rope to withstand alternating loads.
  • Patent No. 201010602411 discloses a wire rope variable load bending fatigue testing machine, which can perform a variable load bending fatigue test on the wire rope standard test piece;
  • Patent No. 201320504867.1 discloses a kind The wire rope bending fatigue testing machine adopts three sets of vertical sliding table, sliding table driving device and four pulley structures, which can monitor the force of the wire rope and the broken wire of the wire rope under the condition of close to the actual working condition.
  • the angle between the wire rope and the pulley is not adjustable, and the internal damage of the wire rope in different corrosive environments cannot be quantitatively monitored; Patent No.
  • Patent No. 201320428225.8 discloses a wire rope bending fatigue test device, which uses two driving wheel devices with different outer diameters to simultaneously perform bending fatigue tests of two steel wire ropes. Save unnecessary time and don't need to take up too much space, but the experimental machine The load is static and the wrap angle cannot be changed and the conditions such as corrosion are not taken into consideration, and the characteristics of the wire rope in actual working conditions cannot be truly reflected.
  • the present invention provides a wire rope bending fatigue damage monitoring system capable of simulating a mine-lifting condition under corrosion-alternating load coupling, under the action of detecting corrosion-alternating load coupling.
  • the internal damage evolution and dynamic tension evolution characteristics of the wire rope and the prediction of the service life of the wire rope are of great significance.
  • a wire rope bending fatigue damage monitoring system under the action of corrosion-alternating load coupling comprising a driving system, an alternating force loading system, a reversing control system, a wrap angle adjusting system, an etching liquid adding system, a wire rope and a wire rope condition monitoring system;
  • the wire rope sequentially bypasses the driving wheel of the driving system, the A adjusting wheel of the wrapping angle adjusting system, the A experimental wheel and the loading wheel of the alternating force loading system, and the wrapping angle adjustment system B experimental wheel, B adjustment wheel, the rope head are connected together to form a closed loop, and the angle of the wire rope and the loading wheel is adjusted by adjusting the A experimental wheel and the B experimental wheel, and the wire rope and the A are respectively adjusted by adjusting the A adjusting wheel and the B adjusting wheel.
  • the wrap angle of the experimental wheel and the B experimental wheel, the three wrap angles are consistent;
  • the reversing control system includes an A proximity switch, a B proximity switch, an A sensor, and a B sensor.
  • the A proximity switch and the B proximity switch are respectively disposed on the A frame and are disposed on both sides of the loading wheel.
  • the A sensing piece and the B sensing piece are respectively fixed on the same side wire rope, and when the A proximity switch and the B proximity switch connected to the external control terminal of the inverter of the commutation control system respectively sense the A sensor piece and a sensing piece, wherein the frequency converter controls a motor of the driving system to change a running direction of the output shaft;
  • the wire rope condition monitoring system comprises a wire rope tension monitoring device, a wire rope damage detecting device, a micro slip monitoring device, and a wire rope radial deformation measuring device;
  • the corrosive liquid addition system is connected to the steel wire rope to add a corrosive liquid to the steel wire rope;
  • the drive system includes an electric motor, and an output shaft of the electric motor sequentially connects the coupling and the driving wheel; the steering of the electric motor is controlled by the inverter.
  • the A proximity switch is operated once, and the counter connected to the A proximity switch is counted once, which is a bending fatigue cycle;
  • the commutation control system further includes an A limit switch and B. Limit switch
  • the electric actuator of the servo electric cylinder of the alternating force loading system passes the pressure sensor Connected to the force receiving bracket, the upper end of the force receiving bracket is sleeved on the shaft of the B experimental wheel, and the lower end is fixed on the wedge sliding table; the loading wheel is disposed on the wedge sliding table; the servo electric cylinder passes The pusher applies an alternating force to the loading wheel, the magnitude of the force being transmitted to the computer via the pressure sensor.
  • the wrapping angle adjustment system includes an A experimental wheel, a B experimental wheel, an A adjusting wheel, and a B adjusting wheel; the A experimental wheel, the B experimental wheel, the A adjusting wheel, and the B adjusting wheel.
  • the axis is located on the same horizontal plane; the A experimental wheel and the B experimental wheel are symmetrically mounted on the A experimental wheel slide and the B test wheel slide, respectively, the test wheel slides relative to the experimental wheel slide; the adjustment wheel and the B adjustment wheel respectively Symmetrically mounted on the A adjustment wheel slide and the B adjustment wheel slide, the adjustment wheel slides relative to the adjustment wheel slide.
  • the etching solution adding system includes a corrosion-resistant sink that stores an etching solution, a corrosion-resistant electric pump, a corrosion-resistant duct, and a rubber tube with a sponge inside; the corrosion-resistant sink and the corrosion-resistant An electric pump is connected, a lower end of the corrosion-resistant conduit is connected to the corrosion-resistant electric pump, an upper end outlet of the corrosion-resistant conduit is aligned with the wire rope, and a corrosion-resistant conduit is used for extracting pH in the corrosion-resistant water tank ⁇ Corrosive liquid; the rubber tube with a sponge inside is fixed through the rubber tube fixing bracket and penetrates the wire rope.
  • the A proximity switch and the B proximity switch are mounted on the A proximity switch bracket and the B proximity switch bracket, and the A limit switch and the B limit switch are respectively mounted on the A limit switch bracket and On the B limit switch bracket, the side of the A proximity switch bracket, the B proximity switch bracket, the A limit switch bracket and the B limit switch bracket are provided with a plurality of threaded holes, and the threaded holes are different from the A frame. The connection between the A proximity switch, the B proximity switch and the A limit switch, the B limit switch, and the corresponding A-sensor and B-sensing sheets is adjusted.
  • the A three-point tension sensor and the B three-point tension sensor are disposed on the A tension sensor slide, and the C three-point tension sensor and the D three-point tension sensor are disposed on the B tension sensor slide, the tension sensor Slide on the slide.
  • the wire rope passes through the A three-point tension sensor, the B three-point tension sensor, the C three-point tension sensor and the D three-point tension sensor which are arranged in a straight line in the longitudinal direction of the wire rope tension monitoring device, respectively, according to the wire rope pair
  • the difference in the force of the three pulleys on the tension sensor is to calculate the tension of the wire rope for monitoring the tension of the wire rope
  • the TCK wire rope non-destructive flaw detector of the wire rope damage detecting device is fixedly connected to the wire rope
  • the micro-slip monitoring device comprises a high-speed camera and a laser displacement sensor disposed outside the A experimental wheel or the B experimental wheel are at the same horizontal position as the wire rope
  • the wire rope radial deformation measuring device monitors the initial displacement value of the wire surface of the wire rope by the laser displacement sensor, Realize dynamic monitoring of the radial deformation of the wire rope.
  • the present invention provides a steel wire rope bending fatigue damage monitoring system under the action of corrosion-alternating load coupling, which can realize the bending fatigue test of the steel wire rope under the coupling of corrosion and alternating load, and quantitatively monitor the internal damage of the steel wire rope and Reveal the failure mechanism of steel wire rope bending fatigue damage.
  • the testing machine can be used to explore the dynamic contact between the wire rope and the friction wheel friction pad under the simulated mine lifting condition, the local micro-slip amplitude and the dynamic tension evolution of the wire rope. This provides an effective experimental equipment for quantitative analysis of the bending fatigue failure characteristics of steel wire rope under complex operating conditions; it is simple in operation, complete in function and good in effect, and has wide practicality in the technical field.
  • Figure 1 is a schematic plan view showing the structure of the present invention
  • FIG. 2 is a schematic front view showing the structure of the present invention
  • Figure 3 is an enlarged view of A in Figure 1.
  • Figure 1 shows a steel wire rope bending fatigue damage monitoring system under the coupling of corrosion-alternating load, including drive system, alternating force loading system, reversing control system, enclosure angle adjustment system, corrosion liquid addition system, wire rope 15 and the wire rope condition monitoring system; further comprising a base price, the base frame comprises an A frame 13 (experimental wheel frame) placed on the ground, a B frame 24 (connecting frame) connected to the A frame 13 , and a B frame 24 Connected C-frame 20 (drive wheel frame), D-rack 35 (high-speed camera and laser displacement sensor frame) and E-frame 38 (corrosion liquid tank stand) placed on the ground, in racks A and B Two pairs of slide tables are respectively arranged on the frame 24: A test wheel slide table 7 and B test wheel slide table 34, A adjustment wheel slide table 22 and B adjustment wheel slide table 19, and A tension sensor slide table is symmetrically arranged in the middle position of the A frame 13 31 and B tension sensor slide table 10, each slide table is divided into upper and lower parts, and the lower part is an I-be
  • the wire rope 15 sequentially bypasses the driving wheel 21 of the driving system, the A adjusting wheel 23 of the wrapping angle adjusting system, the loading wheel 25 of the A experimental wheel 1 and the alternating force loading system, and the B experimental wheel 4 of the wrapping angle adjusting system.
  • B adjusting wheel 18, the rope heads are connected together to form a closed loop, and the angles of the wire rope 15 and the loading wheel 25 are adjusted by adjusting the A test wheel 1 and the B test wheel 4, and are adjusted by adjusting the A adjusting wheel 23 and the B adjusting wheel 18, respectively.
  • the wrap angle of the wire rope 15 and the A test wheel 1 and the B test wheel 4, the three wrap angles are consistent;
  • the reversing control system includes an A proximity switch 27, a B proximity switch 14, an A sensor strip 45, and a B sensor 46.
  • the A proximity switch 27 and the B proximity switch 14 are respectively disposed on the A frame 13, and are disposed on the loading wheel 25.
  • the A sensing piece 45 and the B sensing piece 46 are respectively fixed on the same side wire rope 15, and when the A proximity switch 27 and the B proximity switch 14 connected to the external control terminal of the inverter of the commutation control system respectively sense the A sensor piece 45 and B sensor 46, the inverter controls the motor 42 of the drive system to change the running direction of the output shaft;
  • the wire rope condition monitoring system includes a wire rope tension monitoring device, a wire rope damage detecting device, a micro slip monitoring device, Wire rope radial deformation measuring device;
  • the corrosive liquid addition system is connected to the wire rope 15 to add a corrosive liquid to the wire rope 15;
  • the drive system includes an electric motor 42 whose output shafts are in turn coupled to the coupling 43 and the drive wheel 21; the steering of the electric motor 42 is controlled by the frequency converter.
  • the A proximity switch 27 of the reversing control system is operated once, and the counter connected to the A proximity switch 27 is counted once, which is a bending fatigue cycle; the reversing control system further includes an A limit switch 29 and a B limit switch 16;
  • the proximity switch 27 and the B proximity switch 14 are mounted on the A proximity switch bracket 26 and the B proximity switch bracket 12, and the A limit switch 29 and the B limit switch 16 are respectively mounted on the A limit switch bracket 40 and the B limit switch bracket 44.
  • the side of the A proximity switch bracket 26, the B proximity switch bracket 12, the A limit switch bracket 40, and the B limit switch bracket 44 are provided with a plurality of threaded holes, which are fixedly connected with different threaded holes on the A frame 13.
  • the distance between the proximity switch 27, the B proximity switch 14 and the A limit switch 29, the B limit switch 16 and the A-side sensing piece 45 and the B-sensing piece 46 on the corresponding side meets the requirements of the component positions of different wrapping angles.
  • the servo electric cylinder 2 of the alternating force loading system is fixed on the servo electric cylinder bracket 3, and the electric push rod of the servo electric cylinder 2 is connected to the force receiving bracket 47 through the pressure sensor 11, and the upper end of the force receiving bracket 47 is sleeved on the B experimental wheel 4.
  • the lower end is fixed on the wedge-shaped slide table 28; the loading wheel 25 is disposed on the wedge-shaped slide table 28; the servo-electric cylinder 2 applies an alternating force to the loading wheel 25 through the push rod, and the magnitude of the force changes through the pressure sensor 11 Passed to the computer.
  • the force receiving bracket 47 can make the force applied by the electric push rod of the servo electric cylinder 2 to the loading wheel 25 in the intermediate balance position to reduce the torque received by the wedge sliding table 28, and the wedge sliding table 28 is fixed on the A frame 13;
  • the wrap angle adjustment system includes A test wheel 1, B test wheel 4, A adjustment wheel 23, B adjustment wheel 18; A test wheel 1, B test wheel 4, A adjustment wheel 23, B adjustment wheel 18 axis is at the same horizontal plane
  • the test wheel 1 and the B test wheel 4 are symmetrically mounted on the A test wheel slide table 34 and the B test wheel slide table 7 respectively disposed on the B frame 24 through the connecting shaft and the bearing, and the test wheel slides relative to the test wheel slide table;
  • the adjusting wheel 23 and the B adjusting wheel 18 are symmetrically mounted on the A adjusting wheel stage 22 and the B adjusting wheel stage 19 provided on the B frame 24 by the connecting shaft and the bearing, respectively, and the adjusting wheel slides with respect to the adjusting wheel stage.
  • the etching solution adding system includes a corrosion-resistant water tank 36 for storing the etching liquid, a corrosion-resistant electric pump 37, a corrosion-resistant duct 39, and a rubber tube 48 with a sponge inside; the corrosion-resistant water tank 36 is connected to the corrosion-resistant electric pump 37, and placed together in the E On the frame 38, the lower end of the corrosion-resistant conduit 39 is connected to the corrosion-resistant electric pump 37, the upper end of the corrosion-resistant conduit 39 is aligned with the wire rope 15, and the corrosion-resistant conduit 39 is used to extract the pH 6-12 of the corrosion-resistant water tank 36.
  • Corrosive liquid; a rubber tube 48 with a sponge inside is fixed through the rubber tube fixing bracket 33 and penetrates the wire rope 15, and the internal sponge can bend the fatigue
  • the excess corrosive liquid on the moving wire rope 15 during the process is absorbed to prevent the corrosive liquid from being scattered and splashed.
  • the wire rope 15 passes through the A three-point tension sensor 32, the B three-point tension sensor 30, the C three-point tension sensor 8 and the D three-point tension sensor 9, the A three-point tension sensor 32 and the B three-point tension sensor 30, respectively, which are arranged in the longitudinal direction of the wire rope tension monitoring device.
  • the C three-point tension sensor 8 and the D three-point tension sensor 9 are disposed on the B tension sensor slide table 10, and the tension sensor can slide on the slide table to match the wire rope 15 at different wrap angles. Position requirement; the three-point tension sensor adopts the principle of leverage.
  • the tension of the wire rope is used to monitor the tension of the wire rope, and then the experimental wheel 1 and the experimental wheel 4 are obtained during the bending fatigue process.
  • the tension evolution characteristics of the wire rope 15 on both sides, the three-point tension sensor is made of special stainless steel and has corrosion resistance.
  • the TCK wire rope non-destructive flaw detector 17 of the wire rope damage detecting device is fixedly passed through the wire rope 15 for dynamic real-time monitoring of the wire breakage, wear and corrosion of the wire rope 15 during the bending fatigue process of the wire rope 15 , TCK wire rope nondestructive flaw detector 17 It is placed on the TCK bracket 41; the magnetic flux distribution of the inner wire of the wire rope 15 is different according to different damage conditions, and the qualitative and quantitative characterization of the damage of the wire rope 15 is completed by comparing the difference of the magnetic energy potential of the wire rope before and after the damage.
  • the micro-slip monitoring device comprises a high-speed camera 5 and a laser displacement sensor 6 placed on the outside of the A experimental wheel 1 or the B experimental wheel 4, placed on the D-frame 35, in the same horizontal position as the wire rope 15; Monitoring the micro-slip state of the contact zone between the experimental wheel and the wire rope during the dynamic friction transmission process, the shape of the wire rope and the broken wire strands can be monitored; the laser displacement sensor 6 can dynamically monitor the dynamic creep of the wire rope during the operation on the experimental wheel. change.
  • the wire rope radial deformation measuring device monitors the initial displacement value of the wire surface of the wire rope 15 through the laser displacement sensor 6, thereby realizing dynamic monitoring of the radial deformation of the wire rope.
  • test method for the wire rope bending fatigue damage monitoring system under the coupling of corrosion and alternating load includes the following steps:
  • the wire rope is sequentially bypassed by the driving wheel 21, the A adjusting wheel 23, the A experimental wheel 1, the loading wheel 25, the B experimental wheel 4 and the B adjusting wheel 18, and the positions thereof are sequentially adjusted so that the axes of the respective wheels are on the same horizontal plane; Starting the servo electric cylinder 2, pushing the loading wheel 25, so that the wire rope 15 is tightened, the wire rope tension value reaches an initial small value, and the servo electric cylinder 2 is stopped;
  • the motor 42 is controlled by the frequency converter to drive the driving wheel 21 to rotate. Due to the friction transmission, the wire rope 15 will drive the A test wheel 1, the B experimental wheel 4 and the loading wheel 25 to run together; and simultaneously start the servo electric cylinder 2,
  • the servo electric cylinder 2 applies an alternating force to the loading wheel 25 through the electric push rod, and the magnitude curve of the applied force is transmitted to the computer through the pressure sensor 11, and is displayed on the computer screen in real time, and passes through the PLC electrical control device.
  • the size of the loading force and the loading mode can be controlled;
  • the corrosion-resistant electric pump 37 is activated, and the corrosive liquid in the corrosion-resistant water tank 36 is added to the wire rope 15 through the corrosion-resistant duct 39, and the tension change between the A test wheel 1, the B test wheel 4 and the wire rope 15 is recorded by a three-point tension sensor;
  • the laser displacement sensor 6 monitors the initial displacement value of the wire surface of the wire rope 15 to realize dynamic monitoring of the radial deformation of the wire rope; and records the local micro-slip of the contact zone of the A experimental wheel 1, the B experimental wheel 4 and the wire rope 15 by the high speed camera 5 and Corrosion morphology and broken wire and broken strands of steel wire rope 15;
  • a proximity switch 27 and B proximity switch 14 are externally connected to the external control terminal of the inverter, respectively, and are respectively matched with the A sensing piece 45 and the B sensing piece 46 fixed on the same side wire rope 15, and each time the proximity switch senses the sensing piece, the frequency conversion
  • the motor 42 is controlled to control the motor 42 to change the running direction of the output shaft;
  • the A proximity switch 27 is connected to the counter at the same time, and the counter is counted once every time, which is a bending fatigue cycle;
  • the fatigue state of the wire rope 15 is detected using the TCK wire rope non-destructive tester 17.
  • the motor 42, the servo electric cylinder 2, and the corrosion-resistant electric pump 37 are turned off, and the experiment is finished.

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Abstract

一种腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，包括驱动系统、交变力加载系统、换向控制系统、围包角调整系统、腐蚀液添加系统、钢丝绳（15）及钢丝绳状态监测系统。该监测系统能实现腐蚀与交变载荷耦合作用下钢丝绳弯曲疲劳试验，并且定量监测钢丝绳内部损伤和揭示钢丝绳弯曲疲劳损伤失效机理。可用于探究模拟矿井提升工况下钢丝绳与摩擦轮摩擦衬垫之间的动态接触、局部微滑移幅值和钢丝绳的动张力演化。这为定量分析复杂运行工况下钢丝绳弯曲疲劳失效特性提供了有效的实验设备；其操作简便、功能齐全、效果好。

Description

腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统 技术领域
本发明涉及监测系统，具体是一种腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统。
背景技术
钢丝绳是由多层钢丝捻成股、再由股捻绕成绳的空间螺旋结构，因承载能力好、弯曲柔韧性好、运动平稳无噪音、安全系数大、自重轻等优点被广泛用于各种提升与起重系统。在矿井提升系统中，提升钢丝绳连接矿井提升机和提升容器共同组成了矿井提升系统，担负着提升煤炭、矸石、下放材料、升降人员和设备的任务，一旦钢丝绳失效断裂将导致井毁人亡的重大事故，并且严重影响矿井正常生产和人员的生命安全。由于矿井提升钢丝绳长期处于摩擦、潮湿和腐蚀等工作环境(PH约为6-12)中，并承受着反复的拉伸载荷和弯曲载荷；在矿井提升的过程中，因提升机的加速或减速过程以及时变的悬垂绳长使得提升钢丝绳承受交变载荷的作用。这都会导致钢丝绳内相邻钢丝间微小振幅的微动磨损；如果在微动磨损过程中接触区域存在腐蚀介质，将产生微动腐蚀现象；微动磨损和循环的拉伸载荷或弯曲载荷的共同作用使接触钢丝间发生微动疲劳，引起钢丝表面的裂纹萌生、扩展，最终达到断裂失效，加剧钢丝绳的疲劳断丝失效，缩短了钢丝绳的使用寿命。因此，探究腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤机理和演化特性对提升钢丝绳失效分析有重要意义。然而，现有的传统钢丝绳弯曲疲劳试验机已经不能满足要求，亟需一种能够模拟矿井提升实际工况的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，以探究复杂运行工况下(交变载荷和腐蚀工况)滑轮两侧钢丝绳动张力演化、裂纹萌生和扩展演化、钢丝绳腐蚀动力学特性和钢丝绳服役寿命特性等。
目前，现有钢丝绳弯曲疲劳实验装置包括：专利号为201010602411.X公布了一种钢丝绳变载弯曲疲劳试验机，可对钢丝绳标准试件进行变载弯曲疲劳试验；专利号为201320504867.1公布了一种钢丝绳弯曲疲劳试验机，采用三套作竖直运动的滑台、滑台驱动装置及四个滑轮结构，可在贴近实际工况的条件下监测钢丝绳的受力情况和钢丝绳的断丝情况。然而上述两个试验机中钢丝绳与滑轮间围包角不可调，而且不能对不同腐蚀环境中钢丝绳内部损伤进行定量监测；专利号为201120180376.7公布了一种机械卧式钢丝绳弯曲疲劳试验机，采用与绳径匹配的聚醋摩擦衬垫结构，可以研究不同直径钢丝绳的弯曲疲劳试验，然而该实验机只能做预定载荷下的钢丝绳弯曲疲劳实验，不能模拟交变载荷下的钢丝绳弯曲疲劳行为研究且不能兼顾一些矿井等恶劣条件下的腐蚀等工况；专利号为201320428225.8公布了一种钢丝绳弯曲疲劳试验装置，采用两个外径不同的主动轮装置，可同时进行两种钢丝绳的弯曲疲劳试验，节约不必要的时间，同时也不需要占用过多的空间，然而该实验机的 负载是静态的且围包角不可改变也没能考虑到腐蚀等工况，不能够真实的反映出钢丝绳在实际工况中的特性。
综上，需要一种同时兼具以上各项监测功能的钢丝绳弯曲疲劳试验装置系统，以满足现实所需。
发明内容
发明目的：为了克服现有技术中存在的不足，本发明提供一种能够模拟矿井提升工况的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，对探测腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳过程中钢丝绳内部损伤演化和动张力演化特性和预测钢丝绳使用寿命有重要意义。
技术方案：为实现上述目的，本发明采用的技术方案为：
一种腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，包括驱动系统、交变力加载系统、换向控制系统、围包角调整系统、腐蚀液添加系统、钢丝绳及钢丝绳状态监测系统；
所述钢丝绳依次绕过所述驱动系统的主动轮，所述围包角调整系统的A调整轮、A实验轮和所述交变力加载系统的加载轮，及所述围包角调整系统的B实验轮、B调整轮，绳头连接在一起形成封闭环，通过调整A实验轮和B实验轮调节钢丝绳与加载轮的围包角，通过调整A调整轮和B调整轮分别调节钢丝绳与A实验轮和B实验轮的围包角，三个围包角一致；
所述换向控制系统包括A接近开关、B接近开关、A感应片、B感应片，所述A接近开关和B接近开关分别设置在A机架上，设于所述加载轮的两侧，所述A感应片和B感应片分别固定在同侧钢丝绳上，当与所述换向控制系统的变频器的外控端子连接的A接近开关和B接近开关分别感应到所述A感应片和B感应片，所述变频器控制所述驱动系统的电机改变输出轴的运行方向；
所述钢丝绳状态监测系统包括钢丝绳张力监测装置、钢丝绳损伤探测装置、微滑移监测装置、钢丝绳径向变形测量装置；
所述腐蚀液添加系统与所述钢丝绳连接，为所述钢丝绳添加腐蚀液体；
进一步的，在本发明中，所述驱动系统包括电动机，所述电动机的输出轴依次连接联轴器和主动轮；所述电动机的转向受到变频器的控制。
进一步的，在本发明中，所述A接近开关每动作一次，与所述A接近开关连接的计数器计数一次，即为一个弯曲疲劳周期；所述换向控制系统还包括A限位开关和B限位开关；
进一步的，在本发明中，所述交变力加载系统的伺服电动缸的电动推杆通过压力传感器 与受力支架连接，所述受力支架上端套在所述B实验轮的轴上，下端固定在楔形滑台上；所述加载轮设置在所述楔形滑台上；所述伺服电动缸通过推杆对加载轮施加交变的作用力，所述作用力的大小变化通过所述压力传感器传递给计算机。
进一步的，在本发明中，所述围包角调整系统包括A实验轮、B实验轮、A调整轮、B调整轮；所述A实验轮、B实验轮、A调整轮、B调整轮的轴线位于同一水平面上；所述A实验轮、B实验轮分别对称安装在A实验轮滑台和B实验轮滑台上，所述实验轮相对于实验轮滑台滑动；所述调整轮、B调整轮分别对称安装在A调整轮滑台和B调整轮滑台上，所述调整轮相对于调整轮滑台滑动。
进一步的，在本发明中，所述腐蚀液添加系统包括存储腐蚀液的耐腐蚀水槽、耐腐蚀电动泵、耐腐蚀导管和内部带有海绵的橡胶管；所述耐腐蚀水槽与所述耐腐蚀电动泵连接，所述耐腐蚀导管的下端与所述耐腐蚀电动泵连接，所述耐腐蚀导管的上端出口处对准所述钢丝绳，耐腐蚀导管用于抽取所述耐腐蚀水槽中的pH～的腐蚀液体；所述内部带有海绵的橡胶管通过橡胶管固定支架固定贯穿在钢丝绳上。
进一步的，在本发明中，所述A接近开关和B接近开关安装在A接近开关支架和B接近开关支架上，所述A限位开关和B限位开关分别安装在A限位开关支架和B限位开关支架上，所述A接近开关支架、B接近开关支架、A限位开关支架和B限位开关支架的侧面开有若干个螺纹孔，与所述A机架上不同的螺纹孔固连，调节所述A接近开关、B接近开关和A限位开关、B限位开关与对应侧的A感应片、B感应片间的间距。
进一步的，在本发明中，所述A三点式张力传感器和B三点式张力传感器设置在A张力传感器滑台上，C三点式张力传感器和D三点式张力传感器设置在B张力传感器滑台上，所述张力传感器可在滑台上滑动。
进一步的，在本发明中，所述钢丝绳分别穿过所述钢丝绳张力监测装置的沿纵向直线布置的A三点式张力传感器、B三点式张力传感器、C三点式张力传感器和D三点式张力传感器，根据钢丝绳对所述张力传感器上的三个滑轮的作用力的不同推算出钢丝绳张力进行钢丝绳张力监测；所述钢丝绳损伤探测装置的TCK钢丝绳无损探伤仪固定贯穿在所述钢丝绳上；所述微滑移监测装置包括设置在A实验轮或B实验轮外侧的高速摄像仪和激光位移传感器，与钢丝绳处于同一水平位置；所述钢丝绳径向变形测量装置通过所述激光位移传感器监测钢丝绳顶部钢丝表面的初始位移值，实现动态监测钢丝绳径向变形量。
有益效果：本发明提供的一种腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，能够实现腐蚀与交变载荷耦合作用下钢丝绳弯曲疲劳试验，并且定量监测钢丝绳内部损伤和 揭示钢丝绳弯曲疲劳损伤失效机理。该试验机可用于探究模拟矿井提升工况下钢丝绳与摩擦轮摩擦衬垫之间的动态接触、局部微滑移幅值和钢丝绳的动张力演化。这为定量分析复杂运行工况下钢丝绳弯曲疲劳失效特性提供了有效的实验设备；其操作简便、功能齐全、效果好，在本技术领域内具有广泛的实用性。
附图说明
图1为本发明结构的俯视结构示意图；
图2为本发明结构的主视结构示意图；
图3为图1中的A放大视图。
具体实施方式
下面结合附图对本发明作更进一步的说明。
如图1所示为一种腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，包括驱动系统、交变力加载系统、换向控制系统、围包角调整系统、腐蚀液添加系统、钢丝绳15及钢丝绳状态监测系统；还包括基价，基架包括置于地面上的A机架13(实验轮架)、与A机架13相连的B机架24(连接架)、与B机架24相连的C机架20(主动轮架)、置于地面上的D机架35(高速摄像仪和激光位移传感器架)和E机架38(腐蚀液水槽架)，在A机架13和B机架24上分别设有两对滑台：A实验轮滑台7和B实验轮滑台34、A调整轮滑台22和B调整轮滑台19，A机架13中间位置对称设有A张力传感器滑台31和B张力传感器滑台10，每个滑台分为上下两部分，下部为开有两条平行的两端为半圆弧的长方形通槽的工字钢，上部由轴和轴承组成，通过轴承带动滑轮可以在工字钢上面滑动，通过螺栓将滑轮固定在对应支架上；在A机架13上有一个伺服电动缸支架3。
钢丝绳15依次绕过驱动系统的主动轮21，围包角调整系统的A调整轮23、A实验轮1和交变力加载系统的加载轮25，及围包角调整系统的B实验轮4、B调整轮18，绳头连接在一起形成封闭环，通过调整A实验轮1和B实验轮4调节钢丝绳15与加载轮25的围包角，通过调整A调整轮23和B调整轮18分别调节钢丝绳15与A实验轮1和B实验轮4的围包角，三个围包角一致；
换向控制系统包括A接近开关27、B接近开关14、A感应片45、B感应片46，A接近开关27和B接近开关14分别设置在A机架13上，设于加载轮25的两侧，A感应片45和B感应片46分别固定在同侧钢丝绳15上，当与换向控制系统的变频器的外控端子连接的A接近开关27和B接近开关14分别感应到A感应片45和B感应片46，变频器控制驱动系统的电机42改变输出轴的运行方向；
钢丝绳状态监测系统包括钢丝绳张力监测装置、钢丝绳损伤探测装置、微滑移监测装置、 钢丝绳径向变形测量装置；
腐蚀液添加系统与钢丝绳15连接，为钢丝绳15添加腐蚀液体；
驱动系统包括电动机42，电动机42的输出轴依次连接联轴器43和主动轮21；电动机42的转向受到变频器的控制。
换向控制系统的A接近开关27每动作一次，与A接近开关27连接的计数器计数一次，即为一个弯曲疲劳周期；换向控制系统还包括A限位开关29和B限位开关16；A接近开关27和B接近开关14安装在A接近开关支架26和B接近开关支架12上，A限位开关29和B限位开关16分别安装在A限位开关支架40和B限位开关支架44上，A接近开关支架26、B接近开关支架12、A限位开关支架40和B限位开关支架44的侧面开有若干个螺纹孔，与A机架13上不同的螺纹孔固连，调节A接近开关27、B接近开关14和A限位开关29、B限位开关16与对应侧的A感应片45、B感应片46间的间距，以满足不同围包角对元件位置的需求。
交变力加载系统的伺服电动缸2固定在伺服电动缸支架3上，伺服电动缸2的电动推杆通过压力传感器11与受力支架47连接，受力支架47上端套在B实验轮4的轴上，下端固定在楔形滑台28上；加载轮25设置在楔形滑台28上；伺服电动缸2通过推杆对加载轮25施加交变的作用力，作用力的大小变化通过压力传感器11传递给计算机。受力支架47可以使伺服电动缸2的电动推杆对加载轮25加载的作用力在中间平衡位置，以减小楔形滑台28受到的力矩，楔形滑台28固定在A机架13上；
围包角调整系统包括A实验轮1、B实验轮4、A调整轮23、B调整轮18；A实验轮1、B实验轮4、A调整轮23、B调整轮18的轴线位于同一水平面上；A实验轮1、B实验轮4通过连接轴和轴承分别对称安装于设在B机架24上的A实验轮滑台34和B实验轮滑台7上，实验轮相对于实验轮滑台滑动；调整轮23、B调整轮18通过连接轴和轴承分别对称安装于设在B机架24上的A调整轮滑台22和B调整轮滑台19上，调整轮相对于调整轮滑台滑动。
腐蚀液添加系统包括存储腐蚀液的耐腐蚀水槽36、耐腐蚀电动泵37、耐腐蚀导管39和内部带有海绵的橡胶管48；耐腐蚀水槽36与耐腐蚀电动泵37连接，一起放置在E机架38上，耐腐蚀导管39的下端与耐腐蚀电动泵37连接，耐腐蚀导管39的上端出口处对准钢丝绳15，耐腐蚀导管39用于抽取耐腐蚀水槽36中的pH 6～12的腐蚀液体；内部带有海绵的橡胶管48通过橡胶管固定支架33固定贯穿在钢丝绳15上，其内部海绵可以将弯曲疲劳 过程中运动的钢丝绳15上多余腐蚀液吸收掉，防止腐蚀液体乱滴乱溅。
钢丝绳15分别穿过钢丝绳张力监测装置的沿纵向直线布置的A三点式张力传感器32、B三点式张力传感器30、C三点式张力传感器8和D三点式张力传感器9，A三点式张力传感器32和B三点式张力传感器30设置在A张力传感器滑台31上，C三点式张力传感器8和D三点式张力传感器9设置在B张力传感器滑台10上，张力传感器可在滑台上滑动，以配合不同围包角时钢丝绳15的位置需求；三点式张力传感器采用杠杆原理，根据钢丝绳15对张力传感器上的三个滑轮的作用力的不同推算出钢丝绳张力进行钢丝绳张力监测，进而获得弯曲疲劳过程中A实验轮1和B实验轮4两侧钢丝绳15的张力演化特性，三点式张力传感器由特种不锈钢制成，具有耐腐蚀特性。
钢丝绳损伤探测装置的TCK钢丝绳无损探伤仪17固定贯穿在钢丝绳15上，用于动态实时监测钢丝绳15在弯曲疲劳过程中钢丝绳15的内部钢丝断丝、磨损和腐蚀等状况，TCK钢丝绳无损探伤仪17放置在TCK支架41上；基于不同损伤状况下钢丝绳15内部钢丝的磁力线分布不同，通过对比损伤前后钢丝绳磁能势差异，完成钢丝绳15的损伤的定性和定量化表征。
微滑移监测装置包括位于A实验轮1或B实验轮4外侧，放置于D机架35上的高速摄像仪5和激光位移传感器6，与钢丝绳15处于同一水平位置；高速摄像仪5用于监测动态摩擦传动过程中实验轮与钢丝绳接触区的微滑移状态，可以监测钢丝绳的形貌和断丝断股情况；激光位移传感器6可以动态监测钢丝绳在实验轮上运转的过程中的动态蠕变。
钢丝绳径向变形测量装置通过激光位移传感器6监测钢丝绳15顶部钢丝表面的初始位移值，实现动态监测钢丝绳径向变形量。
实施例
腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统的试验方法，包括如下步骤：
(1)将钢丝绳依次绕过主动轮21、A调整轮23、A实验轮1、加载轮25、B实验轮4和B调整轮18，依次调整其位置，使得各轮轴线位于同一水平面上；启动伺服电动缸2，推动加载轮25，使得钢丝绳15拉紧，钢丝绳张力值达到初始微小值，停止伺服电动缸2；
(2)调整主动轮21、加载轮25、A实验轮1、B实验轮4、A调整轮23和B调整轮18的位置，获得实验所需要的钢丝绳15在A实验轮1、B实验轮4及加载轮25上的围包角且保证三个围包角一致；调节好A三点式张力传感器32、B三点式张力传感器30、C三点式张力传感器8和D三点式张力传感器9、A接近开关27、B接近开关14、A感应片45、B感应片46、A限位开关29和B限位开关的位置，使其处于有效的工作位置；
(3)首先通过变频器对电动机42进行控制，带动主动轮21转动，由于摩擦传动作用钢丝绳15将带动A实验轮1、B实验轮4和加载轮25一起运转；同时启动伺服电动缸2，伺服电动缸2通过电动推杆对加载轮25施加一个交变的力，所施加力的大小变化曲线图通过压力传感器11传递给计算机，并在计算机屏幕上实时显示出来，并且通过PLC电气控制装置可以对加载力的大小和加载方式进行控制；
启动耐腐蚀电动泵37，耐腐蚀水槽36中的腐蚀液通过耐腐蚀导管39添加到钢丝绳15上，通过三点式张力传感器记录A实验轮1、B实验轮4与钢丝绳15之间的张力变化；通过激光位移传感器6监测钢丝绳15顶部钢丝表面的初始位移值，实现动态监测钢丝绳径向变形量；通过高速摄像仪5记录A实验轮1、B实验轮4与钢丝绳15接触区的局部微滑移以及钢丝绳15表面腐蚀形貌和断丝、断股情况；
(4)A接近开关27和B接近开关14外接变频器的外控端子，分别配合固定在同侧钢丝绳15上的A感应片45和B感应片46，每当接近开关感应到感应片，变频器对电动机42进行控制，控制电机42改变输出轴的运行方向；A接近开关27同时连接计数器，其每动作一次，计数器计数一次，即为一个弯曲疲劳周期；
(5)运行一段时间后使用TCK钢丝绳无损检测仪17对钢丝绳15的疲劳状态进行检测，当钢丝绳15达到报废标准后，关闭电动机42、伺服电动缸2和耐腐蚀电动泵37，实验结束。
通过改变伺服电动缸2的加载力大小和力的加载方式、钢丝绳15在实验轮上的围包角、腐蚀液的成分，研究不同的交变力的幅值和变化规律、钢丝绳15绕实验轮不同围包角、模拟不同腐蚀工况下钢丝绳的疲劳失效特性。
以上所述仅是本发明的优选实施方式，应当指出：对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (9)

  1. 腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：包括驱动系统、交变力加载系统、换向控制系统、围包角调整系统、腐蚀液添加系统、钢丝绳(15)及钢丝绳状态监测系统；
    所述钢丝绳(15)依次绕过所述驱动系统的主动轮(21)，所述围包角调整系统的A调整轮(23)、A实验轮(1)和所述交变力加载系统的加载轮(25)，及所述围包角调整系统的B实验轮(4)、B调整轮(18)，绳头连接在一起形成封闭环，通过调整A实验轮(1)和B实验轮(4)调节钢丝绳(15)与加载轮(25)的围包角，通过调整A调整轮(23)和B调整轮(18)分别调节钢丝绳(15)与A实验轮(1)和B实验轮(4)的围包角，三个围包角一致；
    所述换向控制系统包括A接近开关(27)、B接近开关(14)、A感应片(45)、B感应片(46)，所述A接近开关(27)和B接近开关(14)分别设置在A机架(13)上，设于所述加载轮(25)的两侧，所述A感应片(45)和B感应片(46)分别固定在同侧钢丝绳(15)上，当与所述换向控制系统的变频器的外控端子连接的A接近开关(27)和B接近开关(14)分别感应到所述A感应片(45)和B感应片(46)，所述变频器控制所述驱动系统的电机(42)改变输出轴的运行方向；
    所述钢丝绳状态监测系统包括钢丝绳张力监测装置、钢丝绳损伤探测装置、微滑移监测装置、钢丝绳径向变形测量装置；
    所述腐蚀液添加系统与所述钢丝绳(15)连接，为所述钢丝绳(15)添加腐蚀液体；
  2. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述驱动系统包括电动机(42)，所述电动机(42)的输出轴依次连接联轴器(43)和主动轮(21)；所述电动机(42)的转向受到变频器的控制。
  3. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述A接近开关(27)每动作一次，与所述A接近开关(27)连接的计数器计数一次，即为一个弯曲疲劳周期；所述换向控制系统还包括A限位开关(29)和B限位开关(16)；
  4. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述交变力加载系统的伺服电动缸(2)的电动推杆通过压力传感器(11)与受力支架(47)连接，所述受力支架(47)上端套在所述B实验轮(4)的轴上，下端固定在楔形滑台(28)上；所述加载轮(25)设置在所述楔形滑台28)上；所述伺服电动缸(2) 通过推杆对加载轮(25施加交变的作用力，所述作用力的大小变化通过所述压力传感器(11)传递给计算机。
  5. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述围包角调整系统包括A实验轮(1)、B实验轮(4)、A调整轮(23)、B调整轮(18)；所述A实验轮(1)、B实验轮(4)、A调整轮(23)、B调整轮(18)的轴线位于同一水平面上；所述A实验轮(1)、B实验轮(4)分别对称安装在A实验轮滑台(34)和B实验轮滑台(7)上，所述实验轮相对于实验轮滑台滑动；所述调整轮(23)、B调整轮(18)分别对称安装在A调整轮滑台(22)和B调整轮滑台(19)上，所述调整轮相对于调整轮滑台滑动。
  6. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述腐蚀液添加系统包括存储腐蚀液的耐腐蚀水槽(36)、耐腐蚀电动泵(37)、耐腐蚀导管(39)和内部带有海绵的橡胶管(48)；所述耐腐蚀水槽(36)与所述耐腐蚀电动泵(37)连接，所述耐腐蚀导管(39)的下端与所述耐腐蚀电动泵(37)连接，所述耐腐蚀导管(39)的上端出口处对准所述钢丝绳(15)，耐腐蚀导管(39)用于抽取所述耐腐蚀水槽(36)中的pH 6～12的腐蚀液体；所述内部带有海绵的橡胶管(48)通过橡胶管固定支架(33)固定贯穿在钢丝绳(15)上。
  7. 根据权利要求3所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述A接近开关(27)和B接近开关(14)安装在A接近开关支架(26)和B接近开关支架(12)上，所述A限位开关(29)和B限位开关(16)分别安装在A限位开关支架(40)和B限位开关支架(44)上，所述A接近开关支架(26)、B接近开关支架(12)、A限位开关支架(40)和B限位开关支架(44)的侧面开有若干个螺纹孔，与所述A机架(13)上不同的螺纹孔固连，调节所述A接近开关(27)、B接近开关(14)和A限位开关(29)、B限位开关(16)与对应侧的A感应片(45)、B感应片(46)间的间距。
  8. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述A三点式张力传感器(32)和B三点式张力传感器(30)设置在A张力传感器滑台(31)上，C三点式张力传感器(8)和D三点式张力传感器(9)设置在B张力传感器滑台(10)上，所述张力传感器可在滑台上滑动。
  9. 根据权利要求1所述的腐蚀-交变载荷耦合作用下钢丝绳弯曲疲劳损伤监测系统，其特征在于：所述钢丝绳(15)分别穿过所述钢丝绳张力监测装置的沿纵向直线布置的A三点式张力传感器(32)、B三点式张力传感器(30)、C三点式张力传感器(8)和D三点式张力传感器(9)，根据钢丝绳(15)对所述张力传感器上的三个滑轮的作用力的不同推算出 钢丝绳张力进行钢丝绳张力监测；所述钢丝绳损伤探测装置的TCK钢丝绳无损探伤仪(17)固定贯穿在所述钢丝绳(15)上；所述微滑移监测装置包括设置在A实验轮(1)或B实验轮(4)外侧的高速摄像仪(5)和激光位移传感器(6)，与钢丝绳(15处于同一水平位置；所述钢丝绳径向变形测量装置通过所述激光位移传感器(6)监测钢丝绳(15)顶部钢丝表面的初始位移值，实现动态监测钢丝绳径向变形量。
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