Crane steel wire rope flaw detection device and flaw detection method

Abstract

The invention discloses a crane steel wire rope flaw detection device and a flaw detection method, and belongs to the technical field of nondestructive flaw detection. The device comprises a magnetic memory flaw detection module and a wheel type rope climbing robot device for driving the magnetic memory flaw detection module to move along a crane steel wire rope, the magnetic memory flaw detection module comprises a hollow flaw detection shell, the flaw detection shell is longitudinally provided with a central through hole for a crane steel wire rope to penetrate through, and a plurality of giant magneto-impedance effect magnetic sensors are evenly arranged in the flaw detection shell in the circumferential direction of the central through hole. Therefore, a sensor array used for detecting the leakage magnetic field intensity of the crane steel wire rope is formed, and the giant magneto-impedance effect magnetic sensors are arranged in a coplanar mode. The device is mainly based on the giant magneto-impedance effect magnetic sensor and the metal magnetic memory principle, extremely weak magnetic nondestructive testing is conducted on the crane steel wire rope, and the device is convenient to use, high in detection precision, simple in structure and suitable for various steel wire rope detection environments.

Description

Technical Field

[0001] The present invention relates to the technical field of non-destructive testing, and more specifically, to a crane wire rope flaw detection device and a flaw detection method. Background Art

[0002] There are many types of cranes, which are widely used in various fields of the national economy such as mines, metallurgy, construction, water conservancy, tourism, port terminals, transportation, aerospace, oil drilling, and military industries. The market inventory and annual new increment are huge. For cranes, wire ropes are the main components. For a long time, due to the complex structure, harsh use environment, and irreparability of damage, the use and management of wire ropes have always been a difficult point, and even a "blind spot", in the equipment management of each enterprise. Crane wire ropes have also become a major hidden danger to enterprise production safety, and there have been continuous accidents over the years. Therefore, for in-service crane wire ropes, seeking fast and accurate non-destructive testing technologies and means has always been an important issue of concern to users and inspection and testing institutions.

[0003] There are many traditional non-destructive testing technologies, such as: X-rays, ultrasonic waves, magnetic powder, eddy current, γ-rays, penetration (fluorescent, coloring), etc. However, when using the above methods, there are problems such as the need to clean the surface of the object to be inspected, pre-apply solutions or magnetic powder, and clean the attachments after detection. Moreover, the radiation hazards of some methods are relatively large, making it difficult to widely promote and apply them in industrial sites.

[0004] Chinese Patent Application No. CN114544751A discloses a rail flaw detection device and method based on a GMI magnetic sensor, mainly for rail detection. The device includes a mobile flaw detection trolley and a device body installed thereon. The device body is provided with a single-chip microcomputer and multiple GMI magnetic sensors. The GMI magnetic sensors are evenly distributed on the horizontal and vertical plates of the device body, and the cross-section is L-shaped, for detecting the tread and side of the rail. However, this solution can only detect horizontally extending rails and cannot adapt to the complex on-site flaw detection environment of crane wire ropes.

[0005] A Chinese patent application with the publication number CN116973439A discloses a wire rope detection device for a climbing-free device, which includes a primary detection component, a secondary detection component, and a wire rope inspection component. The primary detection component is an alternating current electromagnetic detection device for primary safety detection; the secondary detection component is a magnetic flux leakage non-destructive detection device for secondary safety detection and outputs a magnetic flux leakage image of the wire rope damage. The wire rope inspection component is an infrared recording device for monitoring the operation of the climbing-free device and evaluating the usage status of the wire rope. This device uses machine detection instead of manual detection, avoiding the safety hazards and errors of manual detection. This device is mainly aimed at the wire rope of the climbing-free device inside the wind turbine tower. It uses the primary detection component and the secondary detection component for two detections. The structure is relatively complex and mainly applicable to a specific climbing-free device environment. In terms of structure and protection design, it is difficult to adapt to the complex and changeable industrial detection scenarios such as the wire rope of the crane being at high altitude, outdoors, and with a lot of dust.

[0006] A Chinese patent application with the publication number CN112649495A discloses a wire rope flaw detection device and method. By integrating a magnetic memory planning module, a weak magnetic detection sensor, and a vision camera in a detection housing, it realizes the positioning and visualization of wire rope damage. However, its detection housing is difficult to stably move and operate in a complex environment. There is also the problem of being difficult to adapt to complex industrial detection scenarios. Summary of the Invention

[0007] In view of the problems of insufficient adaptability and efficiency of wire rope flaw detection devices in the prior art, the present invention provides a wire rope flaw detection device and method for a crane. This application uses a wheeled wire rope climbing robot device as a mobile carrier, and uniformly arranges giant magnetoimpedance effect magnetic sensors along the circumferential direction of the crane wire rope to form an annular array, realizing the full-range and full-section detection of the crane wire rope, effectively improving the detection efficiency and coverage rate, and at the same time reducing the risk of manual operation. In addition, the device of this application has a simple structure and strong adaptability, and can be applied to the detection of wire ropes in various complex environments, further improving the reliability and safety of the detection.

[0008] The technical means adopted by the present invention are as follows.

[0009] A wire rope flaw detection device for a crane, comprising: a magnetic memory flaw detection module and a wheeled wire rope climbing robot device that drives the magnetic memory flaw detection module to move along the crane wire rope; the magnetic memory flaw detection module includes a hollow flaw detection housing, a central through hole for the crane wire rope to pass through is longitudinally provided in the flaw detection housing, and a plurality of giant magnetoimpedance effect magnetic sensors are uniformly arranged along the circumferential direction of the central through hole inside the flaw detection housing, thereby forming a sensor array for detecting the magnetic leakage field strength of the crane wire rope, and each giant magnetoimpedance effect magnetic sensor is arranged coplanarly.

[0010] Further, a collection control device is arranged outside the flaw detection housing. The collection control device is signal-connected to each giant magneto-impedance effect magnetic sensor and is used for receiving the leakage magnetic field intensity collected by each giant magneto-impedance effect magnetic sensor.

[0011] Further, the detection directions of the giant magneto-impedance effect magnetic sensors are parallel to the length extension direction of the crane wire rope.

[0012] Further, the wheeled wire rope climbing robot device includes a robot housing. A channel for the crane wire rope to pass through is longitudinally arranged on the robot housing. A driving wheel and a pressing wheel are arranged at the edge of the channel. The driving wheel and the pressing wheel are respectively arranged on both sides of the crane wire rope and engage with the crane wire rope. When the driving wheel rotates driven by a motor, it can cooperate with the pressing wheel to drive the wheeled wire rope climbing robot device to climb along the crane wire rope. An axle angle encoder is arranged on the driving wheel.

[0013] Further, a link mechanism is rotatably arranged inside the robot housing. The pressing wheel is arranged at the upper end of the link mechanism. The lower end of the link mechanism abuts against an adjusting mechanism. The adjusting mechanism has a screw rod, and the screw rod is matched with a threaded hole arranged on the robot housing to realize threaded connection. An adjusting nut is arranged at one end of the screw rod extending out of the threaded opening.

[0014] Further, the adjusting mechanism further includes a buffer spring. One end of the buffer spring is connected to the screw rod, and the other end abuts against the link mechanism.

[0015] Further, a limit protrusion for restricting the movement range of the link mechanism is arranged at a position of the robot housing close to the lower end of the link mechanism.

[0016] Further, a driven wheel is also arranged inside the robot housing. The driven wheel and the pressing wheel are arranged on the same side of the crane wire rope and engage with the crane wire rope.

[0017] Further, a raised structure arranged in a uniform array is arranged on the contact surfaces of the driving wheel, the driven wheel, the pressing wheel and the crane wire rope.

[0018] The present invention also discloses a crane wire rope flaw detection method, which is implemented based on the above-mentioned crane wire rope flaw detection device and includes the following steps: passing the crane wire rope through the central through hole of the flaw detection shell of the magnetic memory flaw detection module and the channel on the robot shell of the wheeled rope climbing robot device for accommodating the crane wire rope; turning on the motor, the motor drives the driving wheel to rotate, the driving wheel cooperates with the pressure wheel to bite the crane wire rope, and drives the entire wheeled rope climbing robot device to climb upward along the crane wire rope under the action of friction; as the wheeled rope climbing robot device drives the magnetic memory flaw detection module to move along the crane wire rope, defects inside the crane wire rope will generate leakage magnetic fields around the crane wire rope, and each giant magneto-impedance effect magnetic sensor uniformly arranged along the circumference of the central through hole inside the flaw detection shell senses the surrounding leakage magnetic field strength and sends the collected leakage magnetic field strength signal to the acquisition control device; after receiving the leakage magnetic field strength signal sent by each giant magneto-impedance effect magnetic sensor, the acquisition control device processes and analyzes it, and then determines whether the crane wire rope has defects and the location information of the defects according to preset standards.

[0019] Compared with the prior art, the present invention has the following advantages.

[0020] 1. This invention utilizes a giant magneto-impedance (GMI) magnetic sensor, leveraging the metal magnetic memory effect, for flaw detection. This technology not only detects flaws on the surface of crane ropes but also deeply examines their internal conditions, with a penetration depth of approximately 15mm. Compared to traditional flaw detection methods, this technology can more comprehensively identify potential defects in crane ropes, such as internal fatigue cracks and broken wires. Its high detection accuracy effectively improves the accuracy and reliability of flaw detection, providing stronger support for crane rope safety assessments.

[0021] 2. The magnetic memory flaw detection module of the present invention is equipped with multiple giant magneto-impedance effect magnetic sensors, which are arranged all around the crane wire rope. This design enables the device to perform full-section inspection of the crane wire rope, ensuring that no potential defects are missed. When the wheeled rope-climbing robot equipped with the magnetic memory flaw detection module moves along the crane wire rope, it can continuously and comprehensively inspect the crane wire rope, greatly improving inspection efficiency, reducing inspection time and labor costs, and achieving rapid and efficient flaw detection of the crane wire rope.

[0022] 3. Single-chip microcomputers are installed inside both the magnetic memory flaw detection module and the wheeled rope-climbing robot device of the present invention. The single-chip microcomputer of the magnetic memory flaw detection module sends the leakage magnetic field intensity signals collected by each giant magneto-impedance effect magnetic sensor to the acquisition control device, and the single-chip microcomputer on the wheeled rope-climbing robot device sends the flaw detection position information of the crane wire rope to the acquisition control device. By using the WIFI communication function of the acquisition control device to connect with the palm computer, remote control operation and data transmission are realized. The operator can control the crane wire rope flaw detection device to perform detection work through the palm computer at a place far from the dangerous area, reducing the risk of manual operation. At the same time, the detection data can be transmitted to the palm computer in real time, facilitating analysis and processing and determining the defect situation of the wire rope, improving the intelligent level of the detection work and the data management efficiency, and being conducive to taking corresponding maintenance measures in time to ensure the safe operation of the crane.

[0023] In summary, the present application realizes the efficient detection of the entire circumference and cross-section of the crane wire rope by adopting the wheeled rope-climbing robot device and the magnetic memory flaw detection module, improving the detection accuracy and coverage rate. At the same time, through the real-time data transmission and remote analysis functions, the risk of manual operation is reduced, the intelligent level of the detection work and the data management efficiency are improved, and the detection reliability and safety in complex environments are ensured. It can be popularized and used in complex industrial detection scenarios. Description of the Drawings

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0025] Figure 1 It is a schematic structural diagram of a crane wire rope flaw detection device in an embodiment of the present invention.

[0026] Figure 2 It is a schematic internal structure diagram of the magnetic memory flaw detection module in an embodiment of the present invention.

[0027] Figure 3(a) is a schematic diagram of magnetic induction lines without defects in defect detection in the embodiment.

[0028] Figure 3(b) is a schematic diagram of magnetic induction lines with defects in defect detection in the embodiment.

[0029] Figure 4 It is a schematic external structure diagram of the wheeled rope-climbing robot device in an embodiment of the present invention.

[0030] Figure 5 It is a schematic internal structure diagram of the wheeled rope-climbing robot device in an embodiment of the present invention.

[0031] In the figure: 1. Magnetic memory flaw detection module; 101. Flaw detection housing; 102. Giant magneto-impedance effect magnetic sensor; 103. Acquisition and control device; 2. Wheeled rope-climbing robot device; 201. Robot housing; 202. First cover plate; 203. Second cover plate; 204. Driving wheel; 205. Adjusting nut; 206. Driven wheel shaft; 207. Motor; 208. Pressing wheel; 209. Link mechanism; 210. Link gland; 211. Driven wheel; 212. Limit projection; 213. Buffer spring; 3. Crane steel wire rope. Specific implementation mode

[0032] In order to enable those skilled in the art to better understand the solution of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

[0033] It should be noted that the terms "first", "second", etc. in the description and claims of the present invention and the above-mentioned drawings are used to distinguish similar objects, and do not have to be used to describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so that the embodiments of the present invention described herein can be implemented in an order other than those illustrated or described herein. In addition, the terms "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device comprising a series of steps or units does not have to be limited to those steps or units clearly listed, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0034] Embodiment 1 This embodiment discloses a flaw detection device for a crane steel wire rope, comprising: a magnetic memory flaw detection module 1 and a wheeled rope-climbing robot device 2 that drives the magnetic memory flaw detection module 1 to move along the crane steel wire rope 3.

[0035] Among them, the magnetic memory flaw detection module 1 includes a hollow flaw detection housing 101. The flaw detection housing 101 is longitudinally provided with a central through hole for the crane steel wire rope 3 to pass through. A plurality of giant magneto-impedance effect magnetic sensors 102 are uniformly arranged along the circumference of the central through hole inside the flaw detection housing 101, so as to form a sensor array for detecting the leakage magnetic field intensity of the crane steel wire rope 3. Each giant magneto-impedance effect magnetic sensor 102 is arranged coplanarly.

[0036] In this embodiment, as Figure 2As shown, each giant magneto-impedance effect magnetic sensor 102 in the magnetic memory flaw detection module 1 is arranged in a ring-shaped equal-angle manner. Preferably, the magnetic memory flaw detection module 1 is equipped with 4-10 giant magneto-impedance effect magnetic sensors 102 according to the diameter of the steel wire rope of the crane to be measured, which are used to measure the leakage magnetic field intensity generated by the damage of the crane steel wire rope, so as to realize the non-destructive flaw detection of the crane steel wire rope. Based on the theory of the metal magnetic memory effect, the high-sensitivity advantage of the giant magneto-impedance effect magnetic sensor 102 is utilized, which can not only perform non-contact flaw detection on the surface of the crane steel wire rope, but also detect its internal part, and the penetration depth can reach about 15-30 mm. Further preferably, the detection direction of each giant magneto-impedance effect magnetic sensor 102 is parallel to the length extension direction of the crane steel wire rope 3.

[0037] This application uses the metal magnetic memory effect to detect defects and stress concentration sites in metal components and structures. The so-called metal magnetic memory effect means that: when ferromagnetic metal parts are processed and operated, due to the combined action of load and geomagnetic field, the magnetic domain structure with magnetostrictive properties will undergo a directional and irreversible reorientation in the stress and deformation concentration areas. This irreversible change in the magnetic state will not only be retained after the working load is removed, but also be related to the maximum acting stress. This magnetic state on the surface of the metal component "remembers" the position of microscopic defects or stress concentration, that is, the so-called magnetic memory effect. When a ferromagnetic component in the geomagnetic field environment is subjected to an external load, a directional and irreversible reorientation of the magnetic domain structure with magnetostrictive properties will occur in the stress concentration area. Fixed nodes of magnetic domains will appear at this part, generating magnetic poles and forming a demagnetizing field, so that the magnetic permeability of the ferromagnetic metal at this part is the smallest, and a leakage magnetic field is formed on the metal surface. The tangential component Hpx of the leakage magnetic field intensity has a maximum value, while the normal component Hpy changes sign and has a zero value. This irreversible change in the magnetic state remains in memory even after the working load is removed.

[0038] The metal magnetic memory detection principle is shown in Figures 3(a) and 3(b). The detection instrument made based on the basic principle of the metal magnetic memory effect can evaluate the stress concentration degree of the component and whether there are microscopic defects by recording the distribution of the magnetic field intensity component perpendicular to the surface of the metal component along a certain direction. It can diagnose the stress concentration area inside the ferromagnetic metal component, that is, microscopic defects, early failure and damage, etc., and prevent sudden fatigue damage. It is a new detection method born with the progress and development of magnetic sensor technology in the non-destructive testing field. Compared with methods such as X-ray, ultrasonic, magnetic powder, eddy current, γ-ray, penetration (fluorescent, coloring), magnetic flux leakage, etc., the metal magnetic memory method has the following advantages: it does not require a special magnetization device; it does not require surface cleaning treatment; it does not require coupling technology; it can quickly and accurately detect stress concentration sites; it can detect existing defects and can also predict future defects according to the change of internal stress.

[0039] When using the giant magneto-impedance effect magnetic sensor 102 to test a brand-new and defect-free single steel wire rope, the magnetic field intensity is completely evenly distributed along the entire length direction, without obvious protrusions and depressions, as shown in Fig. 3(a). When one or more steel wires of the steel wire rope are cut or broken at any position, theoretically, a leakage magnetic field will be generated due to the increase in magnetic resistance at the broken wire position. As a result, there will be obvious protrusions and depressions in the output of the giant magneto-impedance effect magnetic sensor 102 at the corresponding position, and the height and width of the protrusions and depressions are closely related to the number of broken wires, as shown in Fig. 3(b).

[0040] Preferably, in this embodiment, 10 giant magneto-impedance effect magnetic sensors 102 are preferably used to form an annular sensing array to simultaneously detect the flaw detection of the crane steel wire rope 3 located at the center position of the middle through hole of the flaw detection housing 101. The diameter of the middle through hole depends on the thickness of the crane steel wire rope 3, and the former diameter is not greater than the sum of the diameter of the crane steel wire rope 3 and the lift-off distance (0 - 60 mm). The lift-off distance refers to the distance between the giant magneto-impedance effect magnetic sensor 102 and the surface of the object to be measured. The magnetic memory flaw detection module 1 is connected to the wheeled rope-climbing robot device 2 through a copper plate and can also be quickly disassembled and clamped.

[0041] Furthermore, an acquisition and control device 103 is also provided outside the flaw detection housing 101. The acquisition and control device 103 is signal-connected to each giant magneto-impedance effect magnetic sensor 102 for receiving the leakage magnetic field intensity collected by each giant magneto-impedance effect magnetic sensor 102. Preferably, the acquisition and control device 103 can be equipped with a built-in lithium battery or connected to an external power supply. Preferably, the acquisition and control device 103 is also communicatively connected to the shaft angle encoder provided in the wheeled rope-climbing robot device 2 and is connected to a palm computer or a remote computer through the WIFI communication function to transmit the data collected by each giant magneto-impedance effect magnetic sensor 102 and the shaft angle encoder. By moving the wheeled rope-climbing robot device 2 on the crane steel wire rope 3, multiple giant magneto-impedance effect magnetic sensors 102 detect the crane steel wire rope 3 in all directions and at multiple angles, send the detection signals to the palm computer for analysis and processing, and determine the defects of the crane steel wire rope. Through the giant magneto-impedance effect magnetic sensor 102 and the metal magnetic memory effect, not only the surface of the crane steel wire rope 3 can be flaw-detected, but also its interior can be flaw-detected, and a crane steel wire rope with a diameter of up to 55 mm can be detected.

[0042] In this embodiment, the flaw detection housing 101 of the magnetic memory flaw detection module 1 is made of plastic, which is convenient for the wheeled rope-climbing robot device 2 to drive and climb.

[0043] Such as Figure 4 、 5As shown in the figure, the wheeled rope-climbing robot device 2 includes a robot housing 201. A channel for the crane steel wire rope 3 to pass through longitudinally is provided on the robot housing 201. A driving wheel 204 and a pressing wheel 208 are provided at the edge of the channel. The driving wheel 204 and the pressing wheel 208 are respectively arranged on both sides of the crane steel wire rope 3 and engage with the crane steel wire rope 3. When the driving wheel 204 rotates driven by the motor 207, it can cooperate with the pressing wheel 208 to drive the wheeled rope-climbing robot device 2 to climb along the crane steel wire rope 3. An axis angle encoder is provided on the driving wheel 204, and the axis angle encoder is signal-connected to the acquisition and control device 103. The wheeled rope-climbing robot device 2 of the present application can move autonomously on the crane steel wire rope 3, which enables the detection process to be carried out without manual climbing. This not only greatly improves the detection efficiency, but also enhances the operation safety. Moreover, the design is more flexible, capable of adapting to steel wire ropes of different diameters and types, without a complex installation and adjustment process.

[0044] Furthermore, a link mechanism 209 is rotatably arranged inside the robot housing 201. The pressing wheel 208 is arranged at the upper end of the link mechanism 209. The lower end of the link mechanism 209 abuts against an adjusting mechanism. The adjusting mechanism has a screw rod, and the screw rod is matched with a threaded hole provided on the robot housing 201 to achieve a threaded connection. An adjusting nut 205 is provided at one end of the screw rod extending out of the threaded opening. Preferably, the adjusting mechanism further includes a buffer spring 213. One end of the buffer spring 213 is connected to the screw rod, and the other end abuts against the link mechanism 209. The link mechanism 209 is connected inside the robot housing 201 through a rotating shaft. When the screw rod is screwed in, the link mechanism 209 generates a small rotational displacement around the rotating shaft, driving the pressing wheel 208 to move towards the side close to the crane steel wire rope 3, and cooperating with the driving wheel 204 to enhance the clamping force on the crane steel wire rope 3. When the screw rod is screwed out, the link mechanism 209 generates a small rotational displacement around the rotating shaft, driving the pressing wheel 208 to move towards the side away from the crane steel wire rope 3, and cooperating with the driving wheel 204 to reduce the clamping force on the crane steel wire rope 3. A limit protrusion 212 for restricting the movement range of the link mechanism 209 is provided at the position of the robot housing 201 close to the lower end of the link mechanism 209, which is used to prevent the position of the pressing wheel 208 from changing too much and damaging the crane steel wire rope 3. The wheeled rope-climbing robot device 2 of the present application moves stably along the crane steel wire rope 3 through the cooperation of the driving wheel 204 and the pressing wheel 208, reducing the detection error caused by the swing or jitter of the crane steel wire rope 3, and better ensuring the stability of the detection process and the accuracy and reliability of the detection data.

[0045] Preferably, a driven wheel 211 is further provided inside the robot housing 201. The driven wheel 211 and the pressing wheel 208 are arranged on the same side of the crane wire rope 3 and engage with the crane wire rope 3. The contact surfaces of the driving wheel 204, the driven wheel 211, and the pressing wheel 208 with the crane wire rope 3 are provided with raised structures arranged in a uniform array to enhance the friction between the wheel structure and the crane wire rope 3.

[0046] The wheeled rope-climbing robot device 2 of the present application is made of aluminum alloy material or carbon fiber material and is treated with epoxy resin potting, having excellent properties such as waterproof, anti-vibration, and heat insulation, and can operate stably in harsh industrial environments. The requirements for the environment are more relaxed, and there is no need to perform special cleaning or preparation on the wire rope.

[0047] When the crane wire rope flaw detection device works in this embodiment, the driving wheel 204 and the driven wheel 211 are arranged vertically and staggeredly inside the robot housing 201 of the wheeled rope-climbing robot device 2. The wheel shaft of the driving wheel 204 is connected to the output shaft of the motor 207 and is driven by the motor drive shaft, so as to realize the movement of the wheeled rope-climbing robot device 2 on the crane wire rope 3. At the same time, a shaft angle encoder is installed on the wheel shaft of the driving wheel 204. The shaft angle encoder is connected to the port of the acquisition control device 103, and sends the detection signal to the acquisition control device 103. The acquisition control device 103 acquires the detection data of the giant magneto-impedance effect magnetic sensor 102 at preset distance intervals and sends the detection data to the palm computer.

[0048] The shaft angle encoder is installed on the driving wheel 204. Since the wheel diameter of the driving wheel 204 is fixed, the rotation angle of the driving wheel 204 can be detected by the shaft angle encoder and converted into the specific travel of the wheeled rope-climbing robot device 2 climbing along the crane wire rope 3 through numerical transformation. In this embodiment, when the wheeled rope-climbing robot device 2 moves about 1 mm, the acquisition control device 103 reads the detection data of the giant magneto-impedance effect magnetic sensor 102 once, and sends it to the local palm computer together with the time information and the position information through a wired or wireless network, and can be forwarded to the remote server. Thus, the surface magnetic field intensity distribution curve of the crane wire rope is obtained, which is highly correlated with the defect type and grade of the crane wire rope. According to the degree of correlation, it is determined whether the crane wire rope 3 has defects and the type of the defects.

[0049] As a preferred implementation, the magnetic memory flaw detection module 1 can be cylindrical. Different specifications of the magnetic memory flaw detection module 1 are installed on the outside of the robot housing 201 depending on the diameter of the crane wire rope 3 by means of an openable structure such as a hinge, which is convenient for use.

[0050] It should be noted that multiple giant magneto-impedance effect magnetic sensors 102 are equally angularly distributed in the magnetic memory flaw detection module 1, enabling the giant magneto-impedance effect magnetic sensors 102 to detect the crane wire rope 3 in all directions and across the entire cross-section; the distance between the above-mentioned giant magneto-impedance effect magnetic sensors 102 and the surface of the crane wire rope 3 is between 5 mm and 15 mm, preferably 10 mm.

[0051] Embodiment 2 The embodiment of the present invention also provides a method for detecting flaws in a crane wire rope, which is implemented based on a crane wire rope flaw detection device in Embodiment 1 and includes the following steps: S1. Pass the crane wire rope through the central through-hole of the flaw detection housing of the magnetic memory flaw detection module and the passage for the crane wire rope to pass through on the robot housing of the wheeled wire rope climbing robot device.

[0052] Before starting the flaw detection, first, the crane wire rope needs to be passed through the central through-hole of the flaw detection housing of the magnetic memory flaw detection module and the passage on the robot housing of the wheeled wire rope climbing robot device in sequence. Ensure that the crane wire rope passes through each component smoothly, and at the same time, check whether the connection parts of the flaw detection device are firm and reliable, including the connection between the magnetic memory flaw detection module and the wheeled wire rope climbing robot device, and whether the signal connection between each giant magneto-impedance effect magnetic sensor and the acquisition control device is normal. Conduct an insulation check and grounding test before powering on the flaw detection device to ensure the electrical safety of the device during use and prevent equipment damage or personal safety accidents caused by problems such as electric leakage.

[0053] S2. Start the motor, the motor drives the driving wheel to rotate, the driving wheel cooperates with the pressing wheel to bite the crane wire rope, and drives the entire wheeled wire rope climbing robot device to climb upward along the crane wire rope under the action of friction.

[0054] After starting the motor, the motor drives the driving wheel to rotate, and the driving wheel closely cooperates with the pressing wheel and bites on the crane wire rope. Under the action of friction, the entire wheeled wire rope climbing robot device climbs steadily upward along the crane wire rope. The operator can control the climbing speed by adjusting the speed of the motor, generally set between 0.2 - 0.3 m / s to ensure the accuracy of the detection process and the integrity of data acquisition.

[0055] S3. As the wheeled wire rope climbing robot device drives the magnetic memory flaw detection module to move along the crane wire rope, defects inside the crane wire rope will generate leakage magnetic fields around the wire rope. Each giant magneto-impedance effect magnetic sensor uniformly arranged circumferentially along the central through-hole inside the flaw detection housing senses the intensity of the surrounding leakage magnetic fields and sends the collected leakage magnetic field intensity signals to the acquisition control device.

[0056] The giant magneto-impedance effect magnetic sensors arranged circumferentially and uniformly along the central through-hole inside the flaw detection housing, with their detection directions parallel to the length direction of the crane wire rope, can omnidirectionally and sensitively sense the changes in the surrounding leakage magnetic field intensity. Each giant magneto-impedance effect magnetic sensor sends the collected leakage magnetic field intensity signal to the acquisition control device in real time, and the acquisition control device performs preliminary filtering on the received signal to remove high-frequency noise interference, so as to improve the quality and readability of the signal.

[0057] S4. After the acquisition control device receives the leakage magnetic field intensity signals sent by each giant magneto-impedance effect magnetic sensor, it processes and analyzes them, and then judges whether there are defects in the wire rope and the position information of the defects according to the preset standards.

[0058] After the acquisition control device receives the leakage magnetic field intensity signals sent by each giant magneto-impedance effect magnetic sensor, it first preprocesses the signal data. The preprocessing process includes data normalization, which converts the data collected by different sensors with different dimensions and value ranges into the same numerical interval for subsequent unified analysis and comparison. At the same time, through data fusion technology, the data of multiple sensors are fused to improve the reliability and accuracy of the detection results. The acquisition control device is built-in with a special analysis algorithm, and analyzes the processed data according to the preset standards. The preset standards include the leakage magnetic field intensity threshold obtained based on a large amount of experimental data and experience, and the leakage magnetic field characteristic patterns corresponding to different defect types. By comparing the collected data with the preset standards, the acquisition control device can accurately judge whether there are defects in the wire rope and determine the specific position information of the defects. It should be noted that the national standard GBT 5972-2016 "Maintenance, Inspection and Scrap of Crane Wire Ropes" in China classifies its damages into the following ten categories: broken wires, diameter reduction, broken strands, corrosion, deformity and damage, and classifies the damage degree. This application can classify the damages according to the above national standard. In the case of defects, the acquisition control device can remind the operator to take corresponding maintenance measures in time. At the same time, the acquisition control device can also display the flaw detection results on the display screen in an intuitive graphical interface, such as drawing a leakage magnetic field intensity curve graph or a defect position schematic diagram, which is convenient for the operator to quickly understand the health status of the wire rope. In addition, the acquisition control device also has a data storage function, which can store the data of each flaw detection for subsequent data retrospective analysis and establish a health file of the wire rope, providing strong data support for the long-term maintenance and replacement decision of the crane wire rope.

[0059] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some or all of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A flaw detection device for a crane steel wire rope, characterized in that, Including: A magnetic memory flaw detection module and a wheeled rope-climbing robot device for driving the magnetic memory flaw detection module to move along the crane steel wire rope; The magnetic memory flaw detection module includes a hollow flaw detection housing. A central through hole for the crane steel wire rope to pass through is longitudinally provided in the flaw detection housing. A plurality of giant magneto-impedance effect magnetic sensors are uniformly arranged along the circumference of the central through hole inside the flaw detection housing, so as to form a sensor array for detecting the leakage magnetic field strength of the crane steel wire rope. Each giant magneto-impedance effect magnetic sensor is arranged coplanarly.

2. The flaw detection device for a crane steel wire rope according to claim 1, wherein A collection and control device is arranged outside the flaw detection housing. The collection and control device is signal-connected to each giant magneto-impedance effect magnetic sensor and is used for receiving the leakage magnetic field strength collected by each giant magneto-impedance effect magnetic sensor.

3. A crane wire rope flaw detection device according to claim 1, characterized in that, The detection directions of each giant magneto-impedance effect magnetic sensor are parallel to the length extension direction of the crane steel wire rope.

4. A crane wire rope flaw detection device according to any one of claims 1-3, characterized in that, The wheeled rope-climbing robot device includes a robot housing. A channel for the crane steel wire rope to pass through is longitudinally provided on the robot housing. A driving wheel and a pressing wheel are arranged at the edge of the channel. The driving wheel and the pressing wheel are respectively arranged on both sides of the crane steel wire rope and bite with the crane steel wire rope. When the driving wheel rotates driven by a motor, it can cooperate with the pressing wheel to drive the wheeled rope-climbing robot device to climb along the crane steel wire rope. An axle angle encoder is arranged on the driving wheel.

5. The flaw detection device for a crane steel wire rope according to claim 4, characterized in that, A connecting rod mechanism is rotatably arranged inside the robot housing. The pressing wheel is arranged at the upper end of the connecting rod mechanism. The lower end of the connecting rod mechanism abuts against an adjusting mechanism. The adjusting mechanism has a screw rod, and the screw rod is in threaded connection with a threaded hole arranged on the robot housing. An adjusting nut is arranged at one end of the screw rod extending out of the threaded opening.

6. The flaw detection device for a crane wire rope according to claim 5, characterized in that, The adjusting mechanism further includes a buffer spring. One end of the buffer spring is connected to the screw rod, and the other end abuts against the connecting rod mechanism.

7. The flaw detection device for the crane steel wire rope according to claim 6, characterized in that, A limit projection for restricting the movement range of the connecting rod mechanism is arranged at a position of the robot housing close to the lower end of the connecting rod mechanism.

8. A wire rope flaw detection device for a crane according to claim 4, characterized in that, A driven wheel is further arranged inside the robot housing. The driven wheel and the pressing wheel are arranged on the same side of the crane steel wire rope and bite with the crane steel wire rope.

9. The flaw detection device for the crane steel wire rope according to claim 8, characterized in that, Protrusion structures arranged in a uniform array are provided on the contact surfaces of the driving wheel, the driven wheel, and the pressing wheel with the crane steel wire rope.

10. A method for detecting flaws in a crane wire rope, implemented based on the crane wire rope flaw detection device described in claim 1, characterized in that, Including the following steps: Pass the crane steel wire rope through the central through hole of the flaw detection housing of the magnetic memory flaw detection module and the channel for the crane steel wire rope to pass through on the robot housing of the wheeled rope-climbing robot device; Start the motor. The motor drives the driving wheel to rotate. The driving wheel cooperates with the pressing wheel to bite the crane steel wire rope and drives the entire wheeled rope-climbing robot device to climb upward along the crane steel wire rope under the action of friction; As the wheeled rope-climbing robot device drives the magnetic memory flaw detection module to move along the crane steel wire rope, defects inside the crane steel wire rope will generate a leakage magnetic field around the crane steel wire rope. Each giant magneto-impedance effect magnetic sensor uniformly arranged along the circumference of the central through hole inside the flaw detection housing senses the surrounding leakage magnetic field strength and sends the collected leakage magnetic field strength signal to the collection and control device; After receiving the leakage magnetic field intensity signals sent by each giant magneto-impedance effect magnetic sensor, the acquisition control device processes and analyzes them, and then judges whether there are defects in the crane wire rope and the location information of the defects according to the preset criteria.

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