Simulation experiment and visual inspection system for elevator traction steel wire rope

Abstract

The invention discloses an elevator traction steel wire rope simulation experiment and visual detection system, and the system comprises a modeling and simulation module which is used for constructing a steel wire rope three-dimensional model, simulating multi-working-condition mechanical behaviors, and outputting a stress nephogram and a fatigue life curve; the data acquisition and control module is used for acquiring physical test data and driving the bench test device to be synchronous with the data of the simulation experiment system; the data management and analysis module is used for storing simulation and test data and analyzing a performance degradation rule based on a statistical model; and the visualization and interaction module is used for dynamically displaying the simulation process and generating a detection report and early warning information. Compared with a traditional physical experiment, the elevator traction steel wire rope simulation experiment has the advantages that the single-group simulation period is less than or equal to 24 hours, and the time is shortened by 70% compared with the physical experiment; an elevator using unit can be helped to find the defects of the steel wire rope in time and handle or replace the defects in time, potential safety hazards are eliminated, and the occurrence probability of safety accidents is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of performance detection of elevator traction steel wire ropes, in particular to an elevator traction steel wire rope simulation experiment and a visual detection system thereof. Background Art

[0002] The tensile test of a wire rope is an important indicator to measure whether the strength of the wire rope is qualified. Currently, lead-zinc or other alloys are often used in the test to cast the wire rope head into a cone shape suitable for clamping. However, this method has some shortcomings in actual work. On the one hand, the molten metal casting method is harmful to the working environment and the operator. On the other hand, the labor intensity of casting alloys is high, and the cast wire rope end may not be able to adapt to the machine base and jaw design of the tensile test. During the test, in order to adapt to the test environment, many clamps are needed to fix the wire rope end. Due to frequent use, the clamps on the test equipment have poor bite and severe wear at the clamping part. During the wire rope tensile test, the wire rope may fall off or break from the clamping part. This not only makes it impossible to make an accurate judgment on the test results in time, but also affects the progress of testing, research and development, and production.

[0003] Publication No. CN114074887B discloses an automatic timing monitoring system for elevator traction wire ropes. The system includes an inner frame, an outer frame, at least one active rope pulley, at least one passive rope pulley, and a monitoring component. The inner and outer frames are both horizontally arranged and slidably connected to each other. The active rope pulley is located on the inner frame, and the passive rope pulley is located on the outer frame. A gap is left between the active and passive rope pulleys for the traction wire rope to pass through. The monitoring components are located on both the inner and outer frames. This system can automatically and regularly monitor the traction wire rope, reducing the workload of maintenance personnel and ensuring that faults are discovered and alarmed immediately.

[0004] Although the existing technology can realize the detection of traction wire rope, the detection is relatively troublesome and it is impossible to perform simulation experiments on the traction wire rope in advance. Therefore, we propose an elevator traction wire rope simulation experiment and its visual detection system. Summary of the Invention

[0005] The object of the present invention is to provide an elevator traction wire rope simulation experiment and a visual detection system thereof to solve the problems in the prior art.

[0006] To achieve the above object, the present invention provides the following technical solution: an elevator traction wire rope simulation experimental system, comprising:

[0007] Modeling and simulation module, used to build a three-dimensional model of the wire rope, simulate the mechanical behavior of multiple working conditions, and output stress cloud maps and fatigue life curves;

[0008] Data acquisition and control module, collects physical test data, drives the bench test device and the simulation experiment system data synchronization;

[0009] Data management and analysis module, which stores simulation and test data and analyzes performance degradation patterns based on statistical models;

[0010] The visualization and interaction module dynamically displays the simulation process and generates detection reports and early warning information.

[0011] Preferably, the modeling and simulation module includes static analysis, dynamic analysis, fatigue and damage simulation;

[0012] Static analysis is used to simulate the tensile stress of the wire rope under rated load;

[0013] Dynamic analysis is used to simulate the impact load when the elevator starts / stops suddenly;

[0014] Fatigue and damage simulation, set cyclic loading conditions, simulate the crack propagation process through Paris law, establish the "broken wire number-cycle number" relationship curve, and predict the number of cycles required for the wire rope to reach the scrap standard.

[0015] Preferably, the modeling and simulation module further includes corrosion environment simulation and failure mode simulation;

[0016] Corrosion environment simulation is used to simulate the effects of salt spray (NaCl concentration 5%) and moisture (humidity ≥ 90%) on steel wire corrosion and establish a corrosion rate model;

[0017] Failure mode simulation: Reproduce wire breakage, wear, and corrosion defects, and analyze the impact of defects on the overall performance of the wire rope.

[0018] Preferably, the simulation experiment method includes the following steps:

[0019] S1. Data input: Input the material and structural parameters of the wire rope; input the elevator lifting height, operating speed, and load fluctuation range;

[0020] S2. Model construction: A “fiber bundle-strand-rope” multi-level modeling method is used to construct a refined three-dimensional model of the wire rope;

[0021] S3, static analysis to obtain initial stress distribution;

[0022] S4, dynamic analysis simulation dynamic load response;

[0023] S5. Fatigue analysis to predict life and damage evolution;

[0024] S6. Result verification and output: Use a tensile testing machine and a bending fatigue device to verify the simulation results.

[0025] A visual inspection system for an elevator traction steel rope, using the elevator traction steel rope adopted above; comprising:

[0026] The image acquisition unit uses a linear array CCD camera to scan along the axial direction of the wire rope to obtain high-resolution images;

[0027] The camera driving unit drives the camera to move at a constant speed to synchronize the image with the wire rope position;

[0028] Data processing unit, runs image processing algorithms and outputs detection results in real time;

[0029] Human-computer interaction unit displays test results, historical data and warning information.

[0030] Preferably, the image acquisition unit includes an image processing module, which converts the color image into a grayscale image, eliminates random noise by using Gaussian filtering or median filtering, and improves defect contrast by histogram equalization.

[0031] Preferably, it also includes a health assessment module to determine whether the wire rope should be replaced immediately based on the conditions of wire breakage, wear and corrosion.

[0032] Preferably, it also includes a life prediction module, which uses linear regression or LSTM neural network to establish a defect growth model based on historical detection data to predict the time node when the wire rope reaches the scrap standard.

[0033] Preferably, it also includes a database, which is used to store basic information of the wire rope, detection records, and simulation data.

[0034] Preferably, the detection method comprises the following steps:

[0035] S11. Install the linear array CCD camera near the elevator traction machine and adjust the camera position so that the wire rope image covers the center of the field of view; input the wire rope diameter and model, and set the detection speed;

[0036] S12, Image acquisition: The linear array CCD camera scans synchronously with the wire rope, acquiring ≥1000 frames of images per second;

[0037] S13. Pre-process the image and identify defects. If a serious defect is found, the system immediately triggers an audible and visual alarm and sends fault information to the elevator operation and maintenance platform.

[0038] S14. The detection results and image data are stored in a database.

[0039] Compared with the prior art, the present invention has the following beneficial effects:

[0040] 1. Compared with traditional physical experiments, the simulation cycle of a single group of elevator traction wire rope simulation experiments in this application is ≤24 hours, which is 70% shorter than physical experiments. It can help elevator companies optimize wire rope design and reduce R&D costs.

[0041] 2. Real-time detection of surface defects such as broken wires, wear, and rust on wire ropes; measurement of defect size (such as broken wire length and wear depth) to assess the remaining load-bearing capacity of the wire rope; establishment of a performance degradation model based on historical detection data to predict the remaining life and provide a basis for whether to replace the wire rope.

[0042] 3. This system avoids the safety risks of manually climbing on the car roof or in the shaft, making it suitable for online monitoring of operating elevators. From image acquisition to report generation, no human intervention is required, and the inspection time for a single wire rope is ≤ 3 minutes, which is more than 10 times more efficient than traditional visual inspection. Combining defect detection with simulation data (such as stress concentration areas) achieves a closed "detection-analysis-prediction" loop. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0044] Figure 1 It is a flow chart of the simulation experiment of the present invention;

[0045] Figure 2 It is a flow chart of visual inspection of the present invention. DETAILED DESCRIPTION

[0046] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention.

[0047] See also Figure 1 In an embodiment of the present invention, an elevator traction wire rope simulation experiment system includes:

[0048] Modeling and simulation module, used to build a three-dimensional model of the wire rope, simulate the mechanical behavior of multiple working conditions, and output stress cloud maps and fatigue life curves;

[0049] Data acquisition and control module, collects physical test data, drives the bench test device and the simulation experiment system data synchronization;

[0050] Data management and analysis module, which stores simulation and test data and analyzes performance degradation patterns based on statistical models;

[0051] The visualization and interaction module dynamically displays the simulation process and generates detection reports and early warning information.

[0052] Preferably, the modeling and simulation module includes static analysis, dynamic analysis, fatigue and damage simulation;

[0053] Static analysis is used to simulate the tensile stress of the wire rope under rated load (target ≤ allowable stress 1200MPa), focusing on the stress distribution of the rope core and outer steel wire;

[0054] Dynamic analysis is used to simulate the impact load when the elevator starts / stops (acceleration ≤ 1.5m / s 2 ) to analyze the dynamic response characteristics of the wire rope (such as vibration frequency and stress fluctuation);

[0055] Fatigue and damage simulation, set cyclic loading conditions, simulate the crack propagation process through Paris law, establish the "broken wire number-cycle number" relationship curve, and predict the number of cycles required for the wire rope to reach the scrap standard.

[0056] Preferably, the modeling and simulation module further includes corrosion environment simulation and failure mode simulation;

[0057] Corrosion environment simulation is used to simulate the effects of salt spray (NaCl concentration 5%) and moisture (humidity ≥ 90%) on steel wire corrosion and establish a corrosion rate model;

[0058] Failure mode simulation: Reproduce wire breakage, wear, and corrosion defects, and analyze the impact of defects on the overall performance of the wire rope.

[0059] Preferably, the simulation experiment method includes the following steps:

[0060] S1. Data input: Input the material and structural parameters of the wire rope; input the elevator lifting height, operating speed, and load fluctuation range;

[0061] S2. Model construction: A “fiber bundle-strand-rope” multi-level modeling method is used to construct a refined three-dimensional model of the wire rope;

[0062] S3, static analysis to obtain initial stress distribution;

[0063] S4, dynamic analysis simulation dynamic load response;

[0064] S5. Fatigue analysis to predict life and damage evolution;

[0065] S6. Result verification and output: Use a tensile testing machine and a bending fatigue device to verify the simulation results.

[0066] Compared with traditional physical experiments, the elevator traction wire rope simulation experiment has a single group simulation cycle of ≤24 hours, which is 70% shorter than the physical test time; it can help elevator companies optimize wire rope design and reduce R&D costs.

[0067] like Figure 2 , a visual inspection system for an elevator traction wire rope, using the elevator traction wire rope adopted above; comprising,

[0068] The image acquisition unit uses a linear array CCD camera to scan along the axial direction of the wire rope to obtain high-resolution images;

[0069] The camera driving unit drives the camera to move at a constant speed to synchronize the image with the wire rope position;

[0070] Data processing unit, runs image processing algorithms and outputs detection results in real time;

[0071] Human-computer interaction unit displays test results, historical data and warning information.

[0072] Preferably, the image acquisition unit includes an image processing module, which converts the color image into a grayscale image, eliminates random noise by using Gaussian filtering or median filtering, and improves defect contrast by histogram equalization.

[0073] Preferably, it also includes a health assessment module to determine whether the wire rope should be replaced immediately based on the conditions of wire breakage, wear and corrosion.

[0074] Preferably, it also includes a life prediction module, which uses linear regression or LSTM neural network to establish a defect growth model based on historical detection data to predict the time node when the wire rope reaches the scrap standard.

[0075] Preferably, it also includes a database, which is used to store basic information of the wire rope, detection records, and simulation data.

[0076] Preferably, the detection method comprises the following steps:

[0077] S11. Install the linear array CCD camera near the elevator traction machine and adjust the camera position so that the wire rope image covers the center of the field of view; input the wire rope diameter and model, and set the detection speed;

[0078] S12, Image acquisition: The linear array CCD camera scans synchronously with the wire rope, acquiring ≥1000 frames of images per second;

[0079] S13. Pre-process the image and identify defects. If a serious defect is found, the system immediately triggers an audible and visual alarm and sends fault information to the elevator operation and maintenance platform.

[0080] S14. The detection results and image data are stored in a database.

[0081] This system eliminates the safety risks of manually climbing on the car roof or in the hoistway, making it suitable for online monitoring of operating elevators. From image acquisition to report generation, no human intervention is required, and the inspection time for a single wire rope is ≤ 3 minutes, which is over 10 times more efficient than traditional visual inspection. Combining defect detection with simulation data (such as stress concentration areas) creates a closed "detection-analysis-prediction" loop.

[0082] The working principle of the present invention is as follows: a linear array CCD camera is installed near the elevator traction machine, and the camera position is adjusted so that the steel wire rope imaging covers the center of the field of view; the diameter and model of the steel wire rope are input, and the detection speed is set; image acquisition: the linear array CCD camera scans synchronously with the operation of the steel wire rope, and obtains ≥1000 frames of images per second; the image is pre-processed and defect identification is performed. When severe defects are found, the system immediately triggers an audible and visual alarm and sends fault information to the elevator operation and maintenance platform; the detection results and image data are stored in a database; surface defects such as broken wires, wear, and rust of the steel wire rope are detected in real time; the defect size (such as broken wire length and wear depth) is measured to evaluate the remaining load-bearing capacity of the steel wire rope; based on historical detection data, a performance degradation model is established to predict the remaining service life and provide a basis for whether to replace the steel wire rope.

[0083] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art will be able to modify the technical solutions described in the aforementioned embodiments or substitute equivalents for some of the technical features. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention shall be included within the scope of protection of the present invention.

Claims

1. An elevator traction wire rope simulation experiment system, characterized by: include, Modeling and simulation module, used to build a three-dimensional model of the wire rope, simulate the mechanical behavior of multiple working conditions, and output stress cloud maps and fatigue life curves; Data acquisition and control module, collects physical test data, drives the bench test device and synchronizes data with the simulation experiment system; Data management and analysis module, which stores simulation and test data and analyzes performance degradation patterns based on statistical models; The visualization and interaction module dynamically displays the simulation process and generates detection reports and early warning information.

2. The elevator traction wire rope simulation experimental system according to claim 1, characterized in that: The modeling and simulation modules include static analysis, dynamic analysis, fatigue and damage simulation; Static analysis is used to simulate the tensile stress of the wire rope under rated load; Dynamic analysis is used to simulate the impact load when the elevator starts / stops suddenly; Fatigue and damage simulation: set cyclic loading conditions, simulate the crack growth process through Paris law, establish the "broken wire number-cycle number" relationship curve, and predict the number of cycles before the wire rope reaches the scrap standard.

3. The elevator traction wire rope simulation experimental system according to claim 2, characterized in that: The modeling and simulation module also includes corrosion environment simulation and failure mode simulation; Corrosion environment simulation is used to simulate the effects of salt spray and humidity on steel wire corrosion and establish a corrosion rate model; Failure mode simulation: Reproduce wire breakage, wear, and corrosion defects, and analyze the impact of defects on the overall performance of the wire rope.

4. The elevator traction wire rope simulation experimental system according to claim 3, characterized in that: The simulation experiment method includes the following steps: S1. Data input: Input the material and structural parameters of the wire rope; input the elevator lifting height, operating speed, and load fluctuation range; S2. Model construction: A "fiber bundle-strand-rope" multi-level modeling method is used to construct a refined three-dimensional model of the wire rope; S3, static analysis to obtain initial stress distribution; S4, dynamic analysis simulation dynamic load response; S5. Fatigue analysis to predict life and damage evolution; S6. Result verification and output: Use a tensile testing machine and a bending fatigue device to verify the simulation results.

5. A visual inspection system for elevator traction wire ropes, characterized by: Using the elevator traction wire rope used in claims 1-4; include, The image acquisition unit uses a linear array CCD camera to scan along the axial direction of the wire rope to obtain high-resolution images; The camera driving unit drives the camera to move at a constant speed to synchronize the image with the wire rope position; Data processing unit, runs image processing algorithms and outputs detection results in real time; Human-computer interaction unit displays test results, historical data and warning information.

6. The visual inspection system for elevator traction ropes according to claim 5, characterized in that: The image acquisition unit includes an image processing module, which converts a color image into a grayscale image, eliminates random noise using Gaussian filtering or median filtering, and improves defect contrast through histogram equalization.

7. The visual inspection system for elevator traction ropes according to claim 5, characterized in that: It also includes a health assessment module to determine whether the wire rope should be replaced immediately based on the condition of broken wires, wear and corrosion.

8. The visual inspection system for elevator traction ropes according to claim 5, characterized in that: It also includes a life prediction module, which uses linear regression or LSTM neural network to establish a defect growth model based on historical inspection data to predict the time point when the wire rope reaches the scrap standard.

9. The visual inspection system for elevator traction ropes according to claim 5, characterized in that: It also includes a database, which is used to store basic information of the wire rope, detection records, and simulation data.

10. The visual inspection system for elevator traction ropes according to claim 5, characterized in that: The detection method includes the following steps: S11. Install the linear array CCD camera near the elevator traction machine and adjust the camera position so that the wire rope image covers the center of the field of view; input the wire rope diameter and model, and set the detection speed; S12, Image acquisition: The linear array CCD camera scans synchronously with the wire rope, acquiring ≥1000 frames of images per second; S13. Pre-process the image and identify defects. If a serious defect is found, the system immediately triggers an audible and visual alarm and sends fault information to the elevator operation and maintenance platform. S14. The detection results and image data are stored in a database.

Images