Intelligent flaw detection device and detection method thereof

Abstract

The object of the present invention is to provide an intelligent flaw detection device and a detection method thereof, which can detect the entire wire rope, thereby increasing the safety of drilling, and the intelligent flaw detection device is more compact and flexible, reduces manufacturing costs and is more practical. The intelligent flaw detection device is installed on a crown block. The device includes a detection shell and a guide wheel assembly, an encoder, a Hall sensor, a single-chip microcomputer, a pulse turbine probe and a wireless transmission component arranged in the detection shell. At least one group of guide wheel assemblies is arranged in each detection shell, and at least one Hall sensor is arranged at the position of each guide wheel assembly. At least one encoder is connected to each guide wheel assembly, and the single-chip microcomputer, the pulse turbine probe and the wireless transmission component are installed in the corresponding card slot of the detection shell.

Description

Technical Field

[0001] The present invention relates to the field of wire rope flaw detection, and in particular to an intelligent flaw detection device and a detection method thereof. Background Art

[0002] On December 23, 2017, a drilling team was operating the brake handle to start drilling. When the drill was about 2 meters away from the turntable, the fast rope section (35mm) of the drilling wire rope suddenly broke, causing the drill, traveling block, and top drive to fall under their own gravity. The suspended weight dropped from 100 tons to zero in just 3 seconds. First, the elevator touched the drill surface, then the two lifting rings of the top drive cut off the elevator pin and slid out from the center of the turntable. Then the top drive back clamp sat on the drill female joint, and the traveling block and top drive stopped falling. The operation was interrupted for 12 hours, and the direct economic loss was close to 100,000.

[0003] During normal drilling operations, see Fig.13 The top drive is an important part of the top drive drilling system and has been widely promoted and applied. The top drive has the functions of connecting the column, rotating drilling, circulating drilling fluid, etc. Whether the top drive operates normally determines the quality of the drilling conditions. The top drive moves up and down along the derrick, which is an important movement. It moves up and down by the wire rope of the winch. The wire rope is connected to the traveling block through the crown block, and the top drive is connected to the traveling block. It can be said that the wire rope is the backbone of the entire traveling system. Once the wire rope is damaged, it cannot bear the weight, and eventually the top drive falls. It causes the drilling operation to stop, the repair cost to increase, and even life safety accidents.

[0004] In the patent application No. 201910581704.5, an automatic metering and rope arrangement detection device for winches is proposed, which can automatically measure, arrange and detect damage to the wound wire rope. The pulse eddy current probe and Hall sensor are used to detect the use of the wire rope, timely detect the damage of the wire rope, and prevent production safety hazards. However, in the field of drilling, there are sections where the wire rope cannot be detected, such as the fast rope section of the overhead crane. Please refer to Fig.13 When the winch rotates clockwise to lower the top drive to the lower limit height, the wire rope connecting the traveling block and the overhead crane is called the fast rope section. Fig.14 When the winch rotates counterclockwise to lift the top drive to the upper limit height, the fast rope section has not entered the winch drum. If a flaw detection device is installed next to the winch, it is impossible to detect the damage of the fast rope section. The safety of the entire wire rope cannot be guaranteed. Summary of the invention

[0005] The purpose of the present invention is to provide an intelligent flaw detection device and a detection method thereof, which can detect the entire wire rope, thereby increasing drilling safety, and the intelligent flaw detection device is more compact and flexible, reduces manufacturing costs and is more practical.

[0006] The embodiment of the present invention is achieved as follows:

[0007] An intelligent flaw detection device comprises a detection shell and a guide wheel assembly, an encoder, a Hall sensor, a single-chip microcomputer, a pulse turbine probe and a wireless transmission assembly arranged in the detection shell. At least one guide wheel assembly is arranged in each detection shell, at least one Hall sensor is arranged at the position of each guide wheel assembly, at least one encoder is connected to each guide wheel assembly, and the single-chip microcomputer, the pulse turbine probe and the wireless transmission assembly are installed in corresponding card slots of the detection shell.

[0008] In a preferred embodiment of the present invention, the cross-section of the detection housing is octagonal, and a guide wheel assembly, a Hall sensor and an encoder are arranged on each oblique side of the detection housing.

[0009] In a preferred embodiment of the present invention, the above-mentioned detection shell is composed of an upper detection shell and a lower detection shell of the same structure, the upper detection shell and the lower detection shell are connected by bolts, and the upper detection shell is provided with two guide wheel assemblies and a first slot; the lower detection shell is provided with two guide wheel assemblies and a second slot.

[0010] In a preferred embodiment of the present invention, a single chip microcomputer and a pulse turbine probe are arranged in the first card slot, and a wireless transmission component is arranged in the second card slot.

[0011] In a preferred embodiment of the present invention, the above-mentioned intelligent flaw detection device further includes a cover plate and a coil assembly, and the cover plate and the coil assembly are respectively connected to two ends of the detection shell.

[0012] In a preferred embodiment of the present invention, the cover plate is a plate body that matches the shape of the upper detection shell, and connection holes connected to the detection shell are respectively provided at both ends of the cover plate.

[0013] In a preferred embodiment of the present invention, the coil assembly comprises an upper coil component and a lower coil component having the same structure, and the upper coil component and the lower coil component are connected by bolts.

[0014] In a preferred embodiment of the present invention, the above-mentioned upper coil component includes a connecting cover plate, a connecting buckle and an arc-shaped piece. The inner arc of the connecting cover plate is extended with an arc-shaped piece. The connecting buckle is arranged on the outer wall of the arc-shaped piece and the connecting cover plate. The connecting buckle is located at the two end points of the inner arc. The arc-shaped piece is provided with a pulse eddy current probe coil.

[0015] In a preferred embodiment of the present invention, the above-mentioned connecting buckle includes a male buckle and a female buckle, the male buckle and the female buckle are respectively located at the end points of the inner arc, the male buckle is connected to the female buckle of the adjacent intelligent flaw detection device, and the male buckle and the female buckle are connected by bolts.

[0016] A detection method of an intelligent flaw detection device comprises the following steps:

[0017] S1: Install the intelligent flaw detection device on the overhead crane, install one intelligent flaw detection device on each wire rope, connect each intelligent flaw detection device and then power on for self-test;

[0018] S2: When the wire rope moves, when the pulse square wave excitation signal passes through the pulse eddy current probe coil, an alternating magnetic field will be established in the space, and an eddy current flowing in a vortex shape will be formed inside the wire rope. The eddy current of the wire rope forms the magnetic field of the wire rope; the Hall sensor receives the changing magnetic field of the wire rope, and the Hall element converts the changing magnetic field signal into a voltage signal output; the signal is amplified by the Lm358 circuit and then transmitted to the STM32F103C8T6 microcontroller;

[0019] S3: Filter the detection signal and obtain the peak value of the signal collected this time, and compare the peak value of the detection signal with the set defect threshold; if the detection signal this time is less than the set threshold, it indicates that the wire rope here is not defective, and only the detection value of this time needs to be stored, and the encoder feedback value needs to be recorded; if the detection signal this time is greater than the set threshold, it indicates that the wire rope here is defective, and the position of this detection in the entire wire rope is calculated by the encoder feedback value, and the calculation result (defect position) is displayed on the host computer, and an alarm is issued to remind the operator that the wire rope is defective at this point, so as to achieve qualitative analysis of wire rope detection;

[0020] S4: Determine whether the wire rope has been tested. If not, repeat S2, S3, and S4.

[0021] S5: If the wire rope detection is completed, the data is transmitted to the Zigbee transmitter and output to the Zigbee receiver wirelessly, and the data storage and calculation are completed on the host computer, and all the stored detection data are regarded as a sample matrix;

[0022] S6: Calculate the eigenvalues ​​and eigenvectors of the covariance matrix from the sample matrix;

[0023] S7: Obtain the coefficient matrix according to the eigenvalues ​​and eigenvectors of the covariance matrix;

[0024] S8: Combined with the principal component analysis method, the size of the wire rope defect is inverted; the defect size is displayed on the host computer to achieve quantitative analysis of the wire rope defect;

[0025] S9: The wire rope inspection is completed.

[0026] The beneficial effects of the embodiments of the present invention are as follows: the intelligent flaw detection device in the technical solution integrates the encoder, Hall sensor, single-chip microcomputer, pulse turbine probe and wireless transmission component in the detection shell, so that the overall structure of the new flaw detection device is small in size and the manufacturing cost is low. Each intelligent flaw detection device detects a steel wire rope, and then the intelligent flaw detection devices are spliced, so that the movement of the intelligent flaw detection device is more flexible and more practical; and the flaw detection device in the technical solution is installed on the overhead crane, so that the intelligent flaw detection device can detect the damage of the entire steel wire rope, which is safer. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments are briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without creative work.

[0028] Figure 1 This is a schematic diagram of the structure of the intelligent flaw detection device of an embodiment of the present invention when it is assembled;

[0029] Figure 2 A schematic diagram of the explosion structure of an intelligent flaw detection device according to an embodiment of the present invention;

[0030] Figure 3 A schematic diagram of the structure of a coil assembly according to an embodiment of the present invention;

[0031] Figure 4 A schematic diagram of a connection method of a connecting buckle according to an embodiment of the present invention;

[0032] Figure 5 A schematic diagram of the internal structure of a detection housing according to an embodiment of the present invention;

[0033] Figure 6 This is a schematic diagram of the internal structure of the detection housing of an embodiment of the present invention when it is assembled;

[0034] Figure 7 This is a schematic diagram of the structure of the intelligent flaw detection device in a connected state according to an embodiment of the present invention;

[0035] Figure 8 This is a hardware connection diagram of an intelligent flaw detection device according to an embodiment of the present invention;

[0036] Fig. 9 This is an operation flow chart of the intelligent flaw detection device according to an embodiment of the present invention;

[0037] Fig.10 It is a detection flow chart of the intelligent flaw detection device according to an embodiment of the present invention;

[0038] Fig.11 This is a wireless transmission flow chart of the intelligent flaw detection device according to an embodiment of the present invention;

[0039] Fig.12 This is a denoising flow chart of an intelligent flaw detection device according to an embodiment of the present invention;

[0040] Fig.13 This is the installation method of the flaw detection device in the prior art;

[0041] Fig.14 It is a structural schematic diagram of the flaw detection device in the prior art when the winch rotates clockwise;

[0042] Icons: 100-detection housing; 110-guide wheel assembly; 120-encoder; 130-Hall sensor; 140-single-chip microcomputer; 150-pulse turbine probe; 160-wireless transmission assembly; 200-cover; 300-coil assembly; 310-connecting cover; 320-connecting buckle; 330-arc-shaped piece; 321-male buckle; 322-female buckle; 141-amplifier circuit; 161-wireless transmitter; 400-wireless receiver; 500-host computer; 600-power supply; 001-wire hole; 002-connecting hole. DETAILED DESCRIPTION

[0043] 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. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0044] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0045] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0046] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0047] In addition, the terms "horizontal", "vertical", "overhanging" and the like do not mean that the components are required to be absolutely horizontal or overhanging, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0048] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0049] First embodiment

[0050] The intelligent flaw detection device in this embodiment is installed on the overhead travelling crane. In the prior art, the overhead travelling crane is a fixed pulley installed on the top of the derrick, and is mainly composed of components such as the overhead travelling crane frame, pulley, pulley shaft, bearing, bearing seat and auxiliary pulley. During drilling operations, the on-site inspection method is that the derrick worker climbs to the third-level platform and makes a simple judgment by visual inspection. However, human naked eye observation and judgment can only stay on the surface state of the wire rope. In addition, due to the influence of light intensity, it is impossible to conduct a comprehensive inspection of whether there is damage inside the wire rope and the state of all rope sections of the wire rope. These factors have a great impact on timely replacement of wire ropes and ensuring the normal operation of top drive.

[0051] In view of this, this embodiment provides an intelligent flaw detection device, see Figure 1-7, which is installed on the overhead crane of the drilling wire rope, and specifically includes a detection housing 100 and a guide wheel assembly 110, an encoder 120, a Hall sensor 130, a single-chip microcomputer 140, a pulse turbine probe 150 and a wireless transmission component 160 arranged in the detection housing 100. At least one set of guide wheel assemblies 110 is arranged in each detection housing 100, at least one Hall sensor 130 is arranged at the position of each guide wheel assembly 110, at least one encoder 120 is connected to each guide wheel assembly 110, the single-chip microcomputer 140 and the pulse turbine probe 150, and the wireless transmission component 160 are installed in the corresponding card slots of the detection housing 100, and the corresponding card slot positions are shown in FIG. Figure 5-7 .

[0052] More specifically, the cross section of the detection housing 100 in this embodiment is octagonal, and a guide wheel assembly 110, a Hall sensor 130 and an encoder 120 are disposed on each oblique side of the detection housing 100. The detection housing 100 is composed of an upper detection housing and a lower detection housing of the same structure, see Figure 6 , the upper detection housing and the lower detection housing are provided with connection holes 002, and the upper and lower detection housings are connected by bolts. The upper detection housing is provided with two guide wheel assemblies 110 and a first card slot; the lower detection housing is provided with two guide wheel assemblies 110 and a second card slot. The first card slot is provided with a single-chip microcomputer 140 and a pulse turbine probe 150, and the second card slot is provided with a wireless transmission assembly 160. The guide wheel assembly 110 is composed of a guide wheel bracket and a guide wheel, and the wire rope can slide smoothly in the detection housing 100. The card slots in the detection housing in this embodiment are all provided with wire holes 001 for signal lines to connect various devices.

[0053] The intelligent flaw detection device in this embodiment further includes a cover plate 200 and a coil assembly 300 . The cover plate 200 and the coil assembly 300 are respectively connected to two ends of the detection housing 100 .

[0054] The cover plate 200 is a plate body that matches the shape of the upper detection shell. Both ends of the cover plate 200 are respectively provided with connection holes 002 connected to the detection shell 100 for connecting to the detection shell 100. The cover plate 200 and the detection shell 100 are connected by bolts to protect the sensor from external interference.

[0055] The coil assembly 300 includes an upper coil member and a lower coil member of the same structure, which are connected by bolts and are used to wind the coil. The various components of the intelligent flaw detection device in this embodiment are split structures, which is convenient for the installation of the flaw detection device. The upper coil member includes a connecting cover plate 310, a connecting buckle 320 and an arc piece 330. The inner arc of the connecting cover plate 310 is extended with an arc piece 330. The connecting buckle 320 is arranged on the outer wall of the arc piece 330 and the connecting cover plate 310. The connecting buckle 320 is located at the two end positions of the inner arc. The arc piece 330 is provided with a pulse eddy current probe coil.

[0056] More specifically, the connecting buckle 320 in this embodiment includes a male buckle 321 and a female buckle 322. The male buckle 321 and the female buckle 322 are respectively located at the end points of the inner arc. The male buckle 321 is connected to the female buckle 322 of the adjacent intelligent flaw detection device. The male buckle 321 and the female buckle 322 are connected by bolts. In this embodiment, the steel wire rope on the drilling trolley is 6 strands, and 6 units of intelligent flaw detection devices are required to be connected to each other.

[0057] See also Figure 8 The hardware part of the intelligent flaw detection device in this embodiment includes an encoder 120, a Hall sensor 130, a pulse turbine probe 150, an amplifier circuit 141, a single-chip microcomputer 140, a wireless transmitter 161, a wireless receiver 400, a host computer 500 and a power supply 600. The encoder 120, the Hall sensor 130, and the pulse turbine probe 150 are electrically connected to the amplifier circuit 141, the amplifier circuit 141 is connected to the single-chip microcomputer 140, the single-chip microcomputer 140, the wireless transmitter 161, the wireless receiver 400, and the host computer 500 are connected in sequence, and the power supply 600 provides power for the encoder 120, the Hall sensor 130, the pulse turbine probe 150, the amplifier circuit 141, the single-chip microcomputer 140, and the wireless transmitter 161.

[0058] In this embodiment, the pulse turbine probe 150 is used as a magnetic loading device, and the Hall sensor 130 is used for wire rope flaw detection; the single chip microcomputer 140 adopts the arm32-bit data acquisition single chip microcomputer 140STM32F103C8T6, and the wireless transmission uses ZigBee. The host computer 500 is composed of a computer, a special wire rope data processing software, a printer, and a text message notification module. The pulse eddy current probe and the Hall sensor 130 are both electrically connected to the single chip microcomputer 140. When the pulse square wave excitation signal passes through the pulse eddy current probe coil, an eddy current flowing in a vortex shape is formed inside the wire rope, and the wire rope eddy current forms the magnetic field of the wire rope; the Hall sensor 130 receives the changing magnetic field of the wire rope, and the Hall element converts the changing magnetic field signal into a voltage signal. Since the signal change is weak, the Lm358 circuit is used to amplify the signal, and then it is transmitted to the STM32F103C8T6 microcontroller 140 for A / D conversion. There is pulse noise in the data after AD acquisition. In order to effectively filter it out, this paper burns the median filter function in the microcontroller 140, and finally transmits it to the Zigbee transmitter and outputs it to the Zigbee receiver wirelessly, and completes data storage and analysis on the host computer 500.

[0059] This embodiment also provides a detection method of an intelligent flaw detection device, comprising the following steps:

[0060] S1: Install the intelligent flaw detection device on the overhead crane, install one intelligent flaw detection device on each wire rope, connect each intelligent flaw detection device and then power on for self-test;

[0061] S2: When the wire rope moves, when the pulse square wave excitation signal passes through the pulse eddy current probe coil, an alternating magnetic field is established in the space, and an eddy current flowing in a vortex shape is formed inside the wire rope. The eddy current of the wire rope forms the magnetic field of the wire rope; the Hall sensor 130 receives the changing magnetic field of the wire rope, and the Hall element converts the changing magnetic field signal into a voltage signal output; the signal is amplified by the Lm358 circuit and then transmitted to the STM32F103C8T6 microcontroller 140;

[0062] S3: Filter the detection signal and obtain the peak value of the signal collected this time, and compare the peak value of the detection signal with the set defect threshold; if the detection signal this time is less than the set threshold, it indicates that the wire rope here is not defective, and only the detection value of this time needs to be stored, and the feedback value of the encoder 120 needs to be recorded; if the detection signal this time is greater than the set threshold, it indicates that the wire rope here is defective, and the position of this detection in the entire wire rope is calculated by the feedback value of the encoder 120, and the calculation result (defect position) is displayed on the upper computer 500, and an alarm is issued to remind the operator that the wire rope is defective at this point, so as to achieve qualitative analysis of wire rope detection;

[0063] S4: Determine whether the wire rope has been tested. If not, repeat S2, S3, and S4.

[0064] S5: If the wire rope detection is completed, the data is transmitted to the Zigbee transmitter and output to the Zigbee receiver via wireless mode, and the data storage and calculation are completed in the host computer 500, and all the stored detection data are regarded as a sample matrix;

[0065] S6: Calculate the eigenvalues ​​and eigenvectors of the covariance matrix from the sample matrix;

[0066] S7: Obtain the coefficient matrix according to the eigenvalues ​​and eigenvectors of the covariance matrix;

[0067] S8: Inverse the size of the wire rope defect by combining the principal component analysis method; display the defect size on the host computer 500 to achieve quantitative analysis of the wire rope defect;

[0068] S9: The wire rope inspection is completed.

[0069] More specifically, the operating flow chart of the flaw detection device in this embodiment is shown in Fig. 9 , start the host computer 500 to initialize the parameters, and at the same time, the host computer 500 writes the model, diameter, length of the wire rope and the pulse length of the encoder 120 into the single-chip microcomputer 140 wirelessly. After writing, the host computer 500 reads the information of whether the single-chip microcomputer 140 is successfully configured every 2 seconds; after the configuration is successful, start the winch and start the detection mode. The host computer 500 starts to read the wire rope operation data transmitted by the single-chip microcomputer 140, and at the same time processes the detected data and transmits it to the virtual display of the operating console for real-time display. When the host computer 500 writes the stop signal into the single-chip microcomputer 140, the single-chip microcomputer 140 stops sending data and the communication ends.

[0070] For more details, see Fig.10 In the detection flow chart, in the start winch operation process of this embodiment, once the wire rope is detected to be in an abnormal state, the instrument will have an alarm prompt. After the wire rope is fully operated, the automatic detection stops, the results are automatically stored, and a detection process ends. The top drive should be tested in both the up and down directions, and two tests should be performed in the same direction to conduct damage comparison analysis, and to find out whether the test is normal and whether the data is reliable.

[0071] Through the record playback and damage statistics panel of LabVIEW software, historical test records can be played back, analyzed and test reports can be generated. If the test waveform is normal, it means that the wire rope is in good condition. If an abnormal waveform is detected, observe the distance between the abnormal waveform and the start-up, and actually observe the local damage of the wire rope at that location, so as to quickly detect the abnormality of the wire rope.

[0072] For more details, see Fig.11 In the wireless transmission flow chart, the wireless transmission software in this embodiment is mainly designed as a coordinator software, which manages data reception. First, the host computer 500 sends a request instruction through the bus, and then the coordinator determines the address of the request instruction. If the request address matches its own address, a request event is triggered to send data. The receiving network node then returns the data, which is packaged by the address and returned to the host computer 500 through the bus.

[0073] For more details, see Fig.12 In the denoising flow chart, there is impulse noise in the data collected by AD. In order to effectively filter it out, this paper writes the median filter function in the single-chip microcomputer 140. This algorithm is a nonlinear filter. According to a certain point in the time series, the median of all points in the neighborhood of the point is used to replace the point. The filtered data is closer to the true value and effectively eliminates isolated noise points.

[0074] To sum up, the intelligent flaw detection device in the present technical solution integrates the encoder 120, the Hall sensor 130, the single-chip microcomputer 140, the pulse turbine probe 150 and the wireless transmission component 160 in the detection shell 100, so that the overall structure of the new flaw detection device is small in size and the manufacturing cost is low. Each intelligent flaw detection device detects a steel wire rope, and then the intelligent flaw detection devices are spliced, so that the movement of the intelligent flaw detection device is more flexible and more practical; and the flaw detection device in the present technical solution is installed on the overhead crane, so that the intelligent flaw detection device can detect the damage of the entire steel wire rope, which is safer.

[0075] This specification describes examples of embodiments of the present invention, and it is not intended that these embodiments illustrate and describe all possible forms of the present invention. It should be understood that the embodiments in the specification can be implemented in a variety of alternative forms. The drawings need not be drawn to scale; some features can be enlarged or reduced to show the details of specific components. The specific structural and functional details disclosed should not be interpreted as limiting, but are merely representative bases for teaching those skilled in the art to implement the present invention in various forms. It should be understood by those skilled in the art that the multiple features illustrated and described with reference to any of the figures can be combined with the features illustrated in one or more other figures to form embodiments that are not explicitly illustrated or described. The illustrated combined features provide representative embodiments for typical applications. However, various combinations and variations of features consistent with the teachings of the present invention can be used for specific applications or implementations as needed.

[0076] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. An intelligent flaw detection device, It is characterized in that It comprises a detection housing and a guide wheel assembly, an encoder, a Hall sensor, a single-chip microcomputer, a pulse turbine probe and a wireless transmission component arranged in the detection housing, wherein at least one group of the guide wheel assembly is arranged in the detection housing, at least one Hall sensor is arranged at the position of each guide wheel assembly, at least one encoder is connected to each guide wheel assembly, and the single-chip microcomputer, the pulse turbine probe and the wireless transmission component are installed in corresponding card slots of the detection housing; The detection housing is composed of an upper detection housing and a lower detection housing of the same structure, the upper detection housing and the lower detection housing are connected by bolts, the upper detection housing is provided with two guide wheel assemblies and a first slot; the lower detection housing is provided with two guide wheel assemblies and a second slot; The single chip microcomputer and the pulse turbine probe are arranged in the first card slot, and the wireless transmission component is arranged in the second card slot; The intelligent flaw detection device further comprises a cover plate and a coil assembly, wherein the cover plate and the coil assembly are respectively connected to two ends of the detection housing; The cover plate is a plate body that matches the shape of the upper detection shell, and both ends of the cover plate are respectively provided with connection holes connected to the detection shell; The coil assembly comprises an upper coil component and a lower coil component of the same structure, and the upper coil component and the lower coil component are connected by bolts; The upper coil component includes a connecting cover plate, a connecting buckle and an arc-shaped piece. The arc-shaped piece is extended from the inner arc of the connecting cover plate. The connecting buckle is arranged on the outer wall of the arc-shaped piece and the connecting cover plate. The connecting buckle is located at the two end points of the inner arc. The arc-shaped piece is provided with a pulse eddy current probe coil.

2. The intelligent flaw detection device according to claim 1, It is characterized in that The cross section of the detection housing is octagonal, and the guide wheel assembly, the Hall sensor and the encoder are arranged on each oblique side of the detection housing.

3. The intelligent flaw detection device according to claim 1, It is characterized in that The connecting buckle includes a male buckle and a female buckle, the male buckle and the female buckle are respectively located at the end points of the inner arc, the male buckle is connected to the female buckle of the adjacent intelligent flaw detection device, and the male buckle and the female buckle are connected by bolts.

4. A detection method of an intelligent flaw detection device, comprising the intelligent flaw detection device according to any one of claims 1 to 3, It is characterized in that The detection method includes the following steps: S1: Install the intelligent flaw detection device on the overhead crane, install one intelligent flaw detection device on each wire rope, and connect each intelligent flaw detection device and then power on for self-test; S2: The wire rope moves, the magnetic field changes, the Hall sensor receives the magnetic field change and converts it into a voltage signal and transmits it to the amplifier circuit. The detection signal is amplified and then transmitted to the single chip microcomputer; S3: The single chip microcomputer transmits the detection signal to the host computer, which filters the detection signal and obtains the peak value of the signal collected this time, and compares the peak value of the detection signal with the set defect threshold; if the detection signal this time is less than the set threshold, it indicates that the wire rope here is not defective, and only the detection value of this time needs to be stored, and the encoder feedback value needs to be recorded; if the detection signal this time is greater than the set threshold, it indicates that the wire rope here is defective, and the position of this detection in the entire wire rope is calculated through the encoder feedback value, the defect position is displayed on the host computer, and an alarm is issued to remind the operator that the wire rope is defective here, so as to achieve qualitative analysis of wire rope detection; S4: Determine whether the wire rope has been tested. If not, repeat S2, S3, and S4. S5: If the wire rope detection is completed, the data is transmitted to the Zigbee transmitter and output to the Zigbee receiver wirelessly, and the data storage and calculation are completed on the host computer, and all the stored detection data are regarded as a sample matrix; S6: Calculate the eigenvalues ​​and eigenvectors of the covariance matrix from the sample matrix; S7: Obtain the coefficient matrix according to the eigenvalues ​​and eigenvectors of the covariance matrix; S8: Combined with the principal component analysis method, the size of the wire rope defect is inverted; the defect size is displayed on the host computer to achieve quantitative analysis of the wire rope defect; S9: The wire rope inspection is completed.

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