Wire rope inspection device, method, control unit and control system

Abstract

The present application relates to the technical field of detection equipment, and discloses a steel wire rope inspection device, method, control unit and control system. The steel wire rope inspection device comprises a mounting frame, a detection clamp and an oil brush clamp, a camera for shooting a steel wire rope passing through the detection clamp is arranged on the detection clamp, the oil brush clamp and the detection clamp are arranged in parallel and at intervals on the mounting frame, and the jaws of the detection clamp and the oil brush clamp constitute a detection channel for the steel wire rope to pass through. The present application solves the problems of missed detection, wrong detection and misjudgment caused by manual inspection, can accurately determine the surface defects and fatigue damage degree of the steel wire rope, check the internal defects of the steel wire rope which are difficult to check by manual inspection, and determine whether the steel wire rope reaches the scrap standard. The steel wire rope inspection method greatly improves the efficiency and accuracy of the inspection through the automatic inspection mode.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of detection equipment, in particular to a steel wire rope inspection device, method, control unit and control system. BACKGROUND

[0002] Steel wire ropes are widely used, for example, in hoisting equipment for lifting heavy objects. Steel wire ropes need to be regularly inspected for retirement to ensure the safety of equipment and personnel and improve the safety performance of construction and production.

[0003] However, the monitoring of the safety status of steel wire ropes has always been a difficult problem. In the past, artificial visual inspection was mainly used to inspect the broken wires, rust, shrinkage and deformities on the surface of the steel wire rope, and artificial judgment was made on whether the steel wire rope needed to be replaced.

[0004] However, the artificial inspection and judgment method often has missed inspection, wrong inspection and misjudgment, and cannot accurately judge the actual status of the steel wire rope, which may cause safety hazards to the equipment and even cause safety accidents. SUMMARY

[0005] Therefore, the present application provides a steel wire rope inspection device, method, control unit and control system to solve the problem that artificial judgment cannot accurately judge the actual status of the steel wire rope.

[0006] In a first aspect, the present application provides a steel wire rope inspection device, which comprises a mounting frame and a detection clamp, the detection clamp being provided with a camera for shooting a steel wire rope passing through the detection clamp, and an oil brush clamp being arranged on the mounting frame in parallel and at intervals with the detection clamp, the jaws of the detection clamp and the oil brush clamp forming a detection channel for the steel wire rope to pass through.

[0007] Beneficial effects: By providing a camera on the detection clamp, the camera can shoot images of the steel wire rope when the steel wire rope passes through the detection channel. When the steel wire rope moves from the first end to the end in the detection channel, the camera shoots a group of images. These images can be processed to synthesize an image of the full length of the steel wire rope. By analyzing the images, relevant surface data of the steel wire rope can be obtained. Thus, after the steel wire rope has been in operation for a period of time, the surface data obtained by detection and comparison with the initial image of the steel wire rope can be analyzed to obtain the development of broken wires in the full length range, the total number of broken wires of each strand, and other fatigue failure characteristics of the steel wire rope, thereby providing direct data support for judging whether the steel wire rope has reached the retirement standard.

[0008] In an alternative embodiment, the camera is provided with a plurality of cameras arranged at intervals around the circumference of the detection channel.

[0009] Beneficial effects: When multiple cameras are set, the steel wire rope is detected in all directions. Multiple cameras can take images of the same section from different angles. In this way, multiple images of the same section can be processed to synthesize a first surface image of the steel wire rope full circumference at the same section. When the steel wire rope runs completely, multiple first surface image development diagrams can be fitted along the length direction of the steel wire rope. Multiple first surface image development diagrams can also be processed and synthesized to form a second surface image development diagram representing the full length of the rope. Thus, the full circumference and full length of the steel wire rope are detected, ensuring that all positions in the full length of the steel wire rope are monitored, and the detection accuracy is high.

[0010] In an alternative embodiment, the detection clamp and the oil brush clamp each include two oppositely arranged clamp heads, the clamp heads are connected to swing arms, the two swing arms are rotationally connected through a rotating shaft, the swing arms are arranged on the mounting frame, and the swing of the swing arms around the rotating shaft is adapted to drive the opening and closing movement of the two clamp heads.

[0011] Beneficial effects: The swing arms swing to control the opening and closing movement of the two clamp heads. This arrangement is simple, compact, small in size, and has strong adaptability to the working platform site and low system cost.

[0012] In an alternative embodiment, at least three mounting frames are provided, and at least two oil brush clamps are provided. The detection clamp and the oil brush clamp are connected through a pitch driving mechanism and a corresponding mounting frame, respectively. The pitch driving mechanism is adapted to drive the mounting frame to pitch around the rotating shaft.

[0013] Beneficial effects: By providing the pitch driving mechanism, the detection clamp and the oil brush clamp can be driven to rotate around the rotating shaft, respectively. Thus, the coaxiality of the detection clamp and the oil brush clamp with the steel wire rope can be adjusted, and the detection clamp and the oil brush clamp can clamp and inspect the steel wire rope at a reasonable angle in the case of a straight line or various radii of the steel wire rope, thereby improving the detection accuracy.

[0014] In an alternative embodiment, the mounting frame includes a vertical support rod, the rotating shaft is connected to the vertical support rod, the rotating shaft is parallel to the detection channel, and the pitch driving mechanism includes a driven gear connected to the rotating shaft and a driving gear matched with the driven gear.

[0015] Beneficial effects: This arrangement has a simple, compact, small-size transmission structure, strong adaptability to the working platform site, and low system cost. The driving gear can be driven by a pitch driving motor, which is conducive to improving the automation degree of the device in the pre-detection debugging work, reducing manual participation, saving time and effort, and improving the detection efficiency.

[0016] In an alternative embodiment, the mounting frame further includes a horizontal moving seat, the vertical support rod is arranged on the horizontal moving seat, and the horizontal moving seat is connected with a sliding guide mechanism.

[0017] Beneficial effects: By setting the sliding guide mechanism, the horizontal moving seat can slide along the sliding guide mechanism, thereby adjusting the positions of the detection clamp and the oil brush clamp, achieving multi-angle adjustment, ensuring the positions of the detection clamp, the oil brush clamp and the steel wire, and being beneficial to adjusting the camera to the optimal shooting angle, thereby improving the quality of the image of the steel wire and improving the detection accuracy.

[0018] In an alternative embodiment, the sliding guide mechanism comprises a sliding groove and a roller arranged at the bottom of the horizontal moving seat, the horizontal moving seat is slidingly connected to the sliding groove through the roller, and the roller is provided with a self-locking structure.

[0019] Beneficial effects: In this way, the sliding connection is achieved through the roller and the sliding groove, the structure is simple, and smooth movement of the horizontal moving seat can be ensured. Since the roller has a self-locking structure, the roller can be self-locked after adjustment, and the current position can be maintained.

[0020] In an alternative embodiment, a rotary table is further included, and the plurality of mounting frames are arranged on the rotary table through a rotary drive mechanism.

[0021] Beneficial effects: In this way, the orientations of the detection clamp and the oil brush clamp can be adjusted together, thereby ensuring that the detection clamp and the oil brush clamp can reasonably clamp and inspect the steel wire at a reasonable angle in the case of a straight line or various arcs of the steel wire, and improving the detection accuracy.

[0022] In an alternative embodiment, the rotary table comprises a base and a turntable arranged on the base, and the plurality of mounting frames are arranged on the turntable; and the rotary drive mechanism comprises a gear ring connected to the turntable and a rotary gear driving the gear ring to rotate.

[0023] Beneficial effects: In this way, the transmission structure is simple, compact, small in size, and strong in site adaptability of the work platform, and low in system cost. The rotary gear can be driven by a rotary drive motor, which is beneficial to improving the automation degree of the device in the pre-detection debugging work, reducing manual participation, saving time and effort, and improving the work efficiency of detection. Through cooperation with the sliding groove and the roller described above, various direction angles can be adjusted.

[0024] In an alternative embodiment, the vertical support rod comprises a fixed rod and an adjusting rod rotatably connected to the fixed rod through a ball hinge, and the detection clamp and the oil brush clamp are arranged on the corresponding adjusting rods, respectively.

[0025] Beneficial effects: In this way, the adjusting rod can be finely adjusted through the ball hinge, so that the oil brush clamp and the detection clamp are more closely matched with the steel wire, and the detection effect is improved.

[0026] In an alternative embodiment, the vertical support rod is connected with a telescopic adjusting mechanism, and the telescopic adjusting mechanism is suitable for driving the vertical support rod to telescope along the length direction thereof.

[0027] Beneficial effects: In this way, the vertical support rod can be adjusted in length to adjust the height of the detection clamp and the oil brush clamp, so as to adapt to the height of the steel wire and improve the convenience of the device.

[0028] In an alternative embodiment, a first electromagnet is arranged below the base and adapted to be attracted to the equipment to be inspected when powered.

[0029] Beneficial effects: In this way, the entire steel wire inspection device can be fixed on various bases or equipment surfaces by electromagnetic attraction, and various inspection angles can be achieved through the pitch driving mechanism, sliding guide mechanism and telescopic adjustment mechanism, which can not only meet the vertical inspection requirement, but also meet the horizontal inspection requirement and other state steel wire inspection requirements.

[0030] In an alternative embodiment, a second electromagnet is arranged on each swing arm and cooperates with each other, and the second electromagnet is arranged between the rotating shaft and the clamp head.

[0031] Beneficial effects: By arranging the second electromagnet, the two second electromagnets on the two swing arms cooperate with each other, and when detecting, the two second electromagnets are attracted by being powered, so that the two clamp heads are close to each other and tightly closed, and the steel wire inspection operation is performed, thereby further improving the automation degree of the steel wire inspection device.

[0032] In an alternative embodiment, a resilient reset member is connected to the two swing arms of the detection clamp and the oil brush clamp, and the resilient reset member is located on the side of the rotating shaft away from the clamp head.

[0033] Beneficial effects: By arranging the resilient reset member, when the steel wire inspection is completed, the second electromagnet is powered off, and the two swing arms can automatically swing under the elastic force of the resilient reset member to open and reset the two clamp heads, without the need for manual opening of the clamp head, saving time and effort, and facilitating direct placement of the steel wire for the next inspection work, improving the automation degree of the device and improving the work efficiency.

[0034] In an alternative embodiment, two oil brush clamps are arranged on both sides of the detection clamp, and a plurality of circumferentially arranged cameras are arranged on the clamp heads of the detection clamp and the oil brush clamp.

[0035] Beneficial effects: In this way, the number of cameras can be increased, and by reasonably distributing the cameras around the circumference of the steel wire rope, the detection of each cross section of the steel wire rope can be realized. The front and rear of the detection clamp are provided with oil brush clamps, which can clean the steel wire rope and ensure that the pictures taken by the camera can reflect the true situation of the steel wire rope, reduce the interference of stains, and improve the detection accuracy. In addition, the two sides of the detection clamp are provided with oil brush clamps, the oil brush clamp first contacted by the steel wire rope is used for cleaning the steel wire rope to facilitate accurate detection by the rear detection clamp, and the rear oil brush clamp, i.e. the oil brush clamp contacted by the steel wire rope, plays a role in oiling the detected steel wire rope, so that the inspection work of the steel wire rope is completed, and the cleaning and oiling maintenance work of the steel wire rope is also completed, achieving two goals at once.

[0036] In an optional embodiment, a plurality of oil brushes are arranged on the oil brush clamp, and the oil brushes gradually become thinner in the direction close to the detection clamp.

[0037] Beneficial effects: In this way, the thick oil brush is used for cleaning large oil and dirt on the surface of the steel wire rope, and the thin oil brush is used for more detailed cleaning of the surface of the steel wire rope to facilitate detection of the detector on the steel wire rope.

[0038] In a second aspect, the present application provides a control system comprising an industrial computer, a display and a steel wire rope inspection device according to any one of the above technical solutions. The camera is connected to the industrial computer through the signal transceiver device, and the camera is used to shoot the cross-sectional image of the steel wire rope and send the cross-sectional image to the industrial computer. The display is connected to the industrial computer through the signal transceiver device, and the display is used to display the cross-sectional image received by the industrial computer.

[0039] Beneficial effects: Since the control system includes the steel wire rope inspection device, it has all the beneficial effects of the steel wire rope inspection device, which will not be repeated here. In addition, by setting the industrial computer, the automation degree of the steel wire rope inspection can be improved.

[0040] In an optional embodiment, a second electromagnet is arranged on each swing arm of the inspection clamp, and the second electromagnet is electrically connected to the industrial computer.

[0041] Beneficial effects: In this way, the second electromagnet can be powered and de-energized by the industrial computer to control the automatic opening and closing of the detection clamp and the oil brush clamp. Through the coordinated action of each device and part, from the accurate positioning of the measured steel wire rope in the detection preparation stage to the oil removal, detection and data recording and analysis in the detection process, automation can be realized to ensure the quality of the detection work. It is safe. After the device starts working, the worker only needs to remotely monitor the detection data in real time to improve the health protection of the worker.

[0042] In an optional embodiment, a strong and weak magnetic inspection probe is arranged on the detection clamp.

[0043] Beneficial effects: By setting the strong and weak magnetic inspection probe, the internal broken wire can be detected by the method of magnetic detection while the external broken wire of the steel wire rope is inspected. After the detection data is transmitted to the analysis control system, the image development chart can be formed, and the internal data of the steel wire rope can be recorded.

[0044] In an alternative embodiment, the oil brush clamp is connected with an oil supplementing device. The oil supplementing device comprises an oil tank, an oil supplementing pump and an oil injection nozzle which are communicated with each other through an oil supplementing pipeline. The oil tank and the oil supplementing pump are arranged on the rotating disc and can rotate with the rotating disc. The oil injection nozzle is arranged on the oil brush clamp.

[0045] Beneficial effects: In this way, the oil can be supplemented to the steel wire rope after the inspection.

[0046] In an alternative embodiment, a plurality of oil injection nozzles are arranged around the periphery of the clamp opening of the oil brush clamp.

[0047] Beneficial effects: In this way, the oil brush of the oil brush clamp can be uniformly immersed in oil, so that the steel wire rope can be uniformly supplemented with oil on the whole circumferential surface. When two or more oil brush clamps are arranged, the oil supplementing device is connected to each oil brush clamp. In this way, no matter which direction the steel wire rope moves, one oil brush clamp can be used for oil removal and the other oil brush clamp can be used for oil supplementing.

[0048] In an alternative embodiment, the steel wire rope inspection device comprises a driving gear. The driving gear is connected with a pitch driving motor. The pitch driving motor is electrically connected with the industrial computer.

[0049] Beneficial effects: In this way, the automation of the debugging work before the detection of the steel wire rope inspection device can be realized.

[0050] In an alternative embodiment, the steel wire rope inspection device comprises a rotating gear. The rotating gear is connected with a rotating driving motor. The rotating driving motor is electrically connected with the industrial computer.

[0051] Beneficial effects: In this way, the automation of the debugging work before the detection of the steel wire rope inspection device can be realized.

[0052] In an alternative embodiment, the steel wire rope inspection device comprises an oil supplementing pump. The oil supplementing pump is electrically connected with the industrial computer.

[0053] Beneficial effects: In this way, the automation of the debugging work before the detection of the steel wire rope inspection device can be realized.

[0054] In a third aspect, the present application provides a steel wire rope inspection method, comprising the following steps: obtaining cross-sectional images of the steel wire rope at multiple angles around the circumference; fitting the cross-sectional images at multiple angles at the same position into a first surface image development diagram representing the full-circumference surface of the steel wire rope at the position; fitting multiple first surface image development diagrams obtained at multiple positions along the length direction of the steel wire rope; fitting the multiple first surface image development diagrams into a second surface image development diagram representing the surface of the steel wire rope along the full length of the steel wire rope; analyzing the second surface image development diagram to record surface data of the steel wire rope; and determining surface defects of the steel wire rope according to the surface data.

[0055] Beneficial effects: The steel wire rope inspection method provided by the present application can characterize the broken wire development and the total number of broken wires of each strand in the full length of the steel wire rope by detecting and comparing with the initial cross-sectional development diagram after the steel wire rope has been in operation for a period of time, thereby providing direct image data for subsequent steel wire fatigue failure analysis. According to the image data, the surface data of the steel wire rope is recorded, and the surface data of the steel wire rope is analyzed to provide direct data support for determining whether the steel wire rope meets the scrap standard. The surface defects and the degree of fatigue failure of the steel wire rope can be accurately determined by judging the surface data, and it is determined whether the steel wire rope meets the scrap standard, thereby solving the problems of missed inspection, wrong inspection and misjudgment caused by manual inspection. The steel wire rope inspection method provided by the present application can obtain the surface image of the full length and full circumference of the steel wire rope, and has comprehensive detection, high accuracy and good reliability, thereby providing safety protection for the equipment and workers using the steel wire rope.

[0056] In an optional embodiment, the method further comprises the following steps: taking the surface data of the qualified steel wire rope as an initial value, taking the surface data obtained after each inspection as a detection value, point-to-point comparing the difference between the detection value and the initial value, and determining that the steel wire rope is scrapped when the difference reaches a set value.

[0057] Beneficial effects: By using point-to-point comparison and analysis, the defect development of the key defect position of the steel wire rope can be mastered, and it can be accurately determined whether the steel wire rope meets the scrap standard, thereby improving the detection accuracy.

[0058] In an optional embodiment, the method further comprises the following steps:

[0059] While the external broken wire condition of the steel wire rope is inspected, the internal broken wire of the steel wire rope is detected by the magnetic detection method, and an internal image development diagram is fitted; the internal image development diagram is analyzed to record internal data of the steel wire rope; and internal defects of the steel wire rope are determined according to the internal data.

[0060] Beneficial effects: the application can not only check the surface of the steel wire rope, but also detect the internal condition of the steel wire rope through strong magnetic or weak magnetic detection, etc. If the broken wire in the steel wire rope exceeds the standard, it is more dangerous than the damage on the surface of the steel wire rope, so it is more necessary. The method detects the steel wire data more accurately and comprehensively, further improves the safety performance of the steel wire rope equipment, and ensures the personal safety of the workers.

[0061] In an optional embodiment, the following steps are further included: taking the internal data of the qualified steel wire rope as a second initial value, taking the obtained internal data after each inspection as a second detection value, point-to-point comparing the difference between the second detection value and the second initial value, and determining that the steel wire rope is scrapped when the difference reaches a set value.

[0062] Beneficial effects: by adopting point-to-point comparison and analysis, the development of defects in the key defect position of the steel wire rope can be mastered, and whether the steel wire rope reaches the scrapping standard can be accurately judged. The combination of surface data judgment and internal data judgment can comprehensively judge the steel wire rope, and further improve the accuracy of the scrapping judgment of the steel wire rope.

[0063] In an optional embodiment, the surface data includes one or more of the rope diameter, the lay distance or the number of broken wires of the steel wire rope.

[0064] Beneficial effects: these surface data can reflect the fatigue failure characteristics and the fatigue failure degree of the steel wire rope, and feedback various surface defects of the steel wire rope from multiple data, so that the development of the defects of the steel wire rope can be comprehensively detected, and the accuracy of judging whether the steel wire rope reaches the scrapping standard is further improved.

[0065] In an optional embodiment, the surface defects include broken wires, rust, shrinkage or deformation.

[0066] Beneficial effects: by adopting the steel wire rope inspection method provided by the application, the surface defects such as broken wires, rust, shrinkage or deformation can be checked, and the steel wire rope can be comprehensively detected to ensure the accuracy of the detection.

[0067] In an optional embodiment, the following steps are further included:

[0068] Before the cross-sectional images of the steel wire rope at the plurality of circumferential angles are obtained, the steel wire rope is deoiled; and / or after the cross-sectional images of the steel wire rope at the plurality of circumferential angles are obtained, the steel wire rope is oiled.

[0069] Beneficial effects: Degreasing the wire rope before acquiring cross-sectional images of the wire rope from multiple circumferential angles can clean the wire rope, remove oil stains, and ensure the accuracy of the images. After acquiring cross-sectional images of the wire rope from multiple circumferential angles, re-oiling the wire rope can maintain the wire rope and extend its service life.

[0070] Fourthly, the present invention provides a control unit, including an acquisition module, a first image fitting module, a second image fitting module, an analysis module, and a determination module. The acquisition module acquires cross-sectional images of the wire rope at different circumferential angles; the first image fitting module fits multiple cross-sectional images at the same location at multiple angles to form a first surface image unfolded diagram representing the full circumferential surface of the wire rope at that location; multiple first surface image unfolded diagrams are obtained by fitting multiple locations along the length direction of the wire rope; the second image fitting module fits multiple first surface image unfolded diagrams along the length direction of the wire rope to form a second surface image unfolded diagram representing the surface of the wire rope along its entire length; the analysis module analyzes the second surface image unfolded diagram and records the surface data of the wire rope; the determination module determines the surface defects present in the wire rope based on the surface data.

[0071] In one optional implementation, a third image fitting module is also included. The third image fitting module is used to detect internal wire breakage of the wire rope by magnetic detection while inspecting the external wire breakage of the wire rope, and to fit and form an internal image unfolding diagram. The analysis module is also used to analyze the internal image unfolding diagram and record the internal data of the wire rope. The determination module is also used to determine the internal defects of the wire rope based on the internal data.

[0072] Beneficial effects: The control unit corresponds to the wire rope inspection method, therefore, it has the same technical effects as the wire rope inspection method, which will not be elaborated here. Attached Figure Description

[0073] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0074] Figure 1 This is a top view of a wire rope inspection device according to an embodiment of the present invention;

[0075] Figure 2 for Figure 1 Side view of the inspection clamp in the wire rope inspection device shown;

[0076] Figure 3 forFigure 1 Side view of the oil brush pliers in the steel wire rope inspection device shown;

[0077] Figure 4 Structure schematic diagram of a control system for an embodiment of the present application;

[0078] Figure 5 Flow schematic diagram of a steel wire rope inspection method for an embodiment of the present application;

[0079] Figure 6 Flow schematic diagram of another steel wire rope inspection method for an embodiment of the present application;

[0080] Figure 7 Composition block diagram of a control unit for an embodiment of the present application.

[0081] Explanation of reference numerals:

[0082] 1, mounting frame; 101, transverse moving seat; 103, vertical support rod; 1031, fixed rod; 1032, adjusting rod; 1033, spherical hinge; 21, detection pliers; 22, oil brush pliers; 202, plier head; 203, swing arm; 204, rotating shaft; 23, detection channel; 3, camera; 4, pitch driving mechanism; 401, pitch driving motor; 402, driving gear; 403, driven gear; 5, sliding guide mechanism; 501, sliding groove; 502, roller; 6, second electromagnet; 7, elastic return member; 8, industrial computer; 9, display; 10, signal transceiver device; 20, signal antenna; 30, oil brush; 40, rotary table; 4001, base; 4002, rotating disc; 50, rotary driving mechanism; 5001, gear ring; 5002, rotary gear; 5003, rotary driving motor; 60, telescopic adjusting mechanism; 70, strong and weak magnetic inspection probe; 80, oil supplement device; 8001, oil tank; 8002, oil supplement pump; 8003, oil injection nozzle; 8004, oil supplement pipeline; 100, steel wire rope; 110, acquisition module; 120, first image fitting module; 130, second image fitting module; 140, analysis module; 150, determination module. DETAILED DESCRIPTION

[0083] To make the objectives, technical solutions and advantages of embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described below in connection with the drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0084] The application solves the problems of missed detection, wrong detection and misjudgment caused by manual inspection, can accurately determine the surface defects and fatigue damage degree of the steel wire rope, and check the internal defects of the steel wire rope which are difficult to check by manual inspection, and determine whether the steel wire rope reaches the scrap standard. The method greatly improves the efficiency and accuracy of the inspection through the automatic inspection method.

[0085] The embodiments of the application will be described below in combination with Figures 1 to 7

[0086] According to the embodiments of the application, in a first aspect, a steel wire rope inspection device is provided, which comprises a mounting frame 1 and a detection clamp 21, the detection clamp 21 is provided with a camera 3 for shooting the steel wire rope 100 passing through the detection clamp 21, and an oil brush clamp 22 is arranged on the mounting frame 1 in parallel with the detection clamp 21, and the clamping openings of the detection clamp 21 and the oil brush clamp 22 constitute a detection channel 23 for the steel wire rope 100 to pass through.

[0087] By arranging the camera 3 on the detection clamp 21, the camera 3 can shoot the images of the steel wire rope 100 when the steel wire rope 100 passes through the detection channel 23, and a set of images can be shot by the camera 3 when the steel wire rope 100 moves in the detection channel 23 from the first end to the last end. These images can be combined into the image of the whole length of the steel wire rope 100 after processing, and the relevant surface data of the steel wire rope 100 can be obtained by analyzing the images. Thus, after the steel wire rope 100 works for a period of time, the development of the broken wires in the whole length range and the total number of broken wires of each strand of the steel wire rope 100 can be obtained by detecting and comparing and analyzing the surface data fed back by the initial images of the steel wire rope 100, thereby providing direct data support for judging whether the steel wire rope 100 reaches the scrap standard.

[0088] In the related art, the cleaning scheme for the steel wire rope inspection is to immerse the steel wire rope to be detected into a solvent in a dissolving tank to dissolve the oil on the surface of the steel wire rope. However, such a wet cleaning scheme has the following technical problems: 1. The solvent immersed into the steel wire rope can corrode the oil remaining in the inner layer of the steel wire rope for protecting the inner steel wire rope, resulting in defects and accelerated damage of the inner layer of the steel wire rope. The inner layer of the steel wire rope is more difficult to inspect and the defects are more dangerous. 2. The residual solvent will have a long-term corrosive effect on the steel wire rope, especially the solvent remaining in the inner layer of the steel wire rope, which is difficult to clean completely in the subsequent drying process and will continuously corrode the inner steel wire.

[0089] ​The steel wire rope inspection device provided by the embodiment adopts the oil brush pliers to clean the oil stains of the steel wire rope, adopts the dry cleaning method, and can effectively solve the above two technical problems. In addition, the oil brush pliers can completely cover the steel wire rope, so that the entire outer surface of the steel wire rope can be comprehensively cleaned, there is no blind area for cleaning between the oil brush pliers and the steel wire rope, the cleaning effect is good, and the quality of subsequent steel wire rope inspection is ensured.

[0090] In one embodiment, the camera 3 is provided in multiple numbers and is arranged at intervals around the circumference of the detection channel 23.

[0091] When multiple cameras 3 are provided, the steel wire rope 100 is detected in all directions for each cross section. The multiple cameras 3 can capture images of the same cross section from different angles, so that multiple images of the same cross section can be processed to synthesize a first surface image development diagram of the full circumference of the steel wire rope 100 at the cross section. When the steel wire rope 100 travels a full course, multiple first surface image development diagrams can be fitted along the length direction of the steel wire rope 100, and multiple first surface image development diagrams can also be processed and synthesized to form a second surface image development diagram representing the full length, so that the full circumference and full length of the steel wire rope 100 can be detected, and all positions in the full length range of the steel wire rope 100 are monitored, and the detection accuracy is high.

[0092] In one embodiment, the detection pliers 21 and the oil brush pliers 22 each include two oppositely arranged plier heads 202, the plier heads 202 are connected to swing arms 203, the two swing arms 203 are rotationally connected through a rotation shaft 204, the swing arms 203 are arranged on the mounting frame 1, and the swing of the swing arms 203 around the rotation shaft 204 is suitable for driving the opening and closing movement of the two plier heads 202.

[0093] The swing arms 203 swing to control the opening and closing movement of the two plier heads 202, and such a structure is simple, compact, small in size, and strong in adaptability to the working platform site, and low in system cost.

[0094] In one embodiment, the mounting frame 1 is provided in at least three numbers, the oil brush pliers 22 are provided in at least two numbers, the detection pliers 21 and the oil brush pliers 22 are respectively connected through the pitch driving mechanism 4 and the corresponding mounting frame 1, and the pitch driving mechanism 4 is suitable for driving the mounting frame 1 to pitch and swing around the rotation shaft 204.

[0095] The pitch driving mechanism 4 can drive the detection pliers 21 and the oil brush pliers 22 to rotate around the rotation shaft 204, respectively, so that the coaxiality of the detection pliers 21 and the oil brush pliers 22 and the steel wire rope 100 can be adjusted, and the detection pliers 21 and the oil brush pliers 22 can clamp and inspect the steel wire rope 100 at a reasonable angle under the condition that the steel wire rope 100 is in a straight line or has various radii, so that the detection accuracy is improved.

[0096] In one embodiment, the detection clamp 21 is provided with one, the oil brush clamp 22 is provided with two, and the two oil brush clamps 22 are respectively arranged on the two sides of the detection clamp 21, so that the steel wire rope 100 can be cleaned by the oil brush clamp 22 first and then detected by the detection clamp 21 no matter it moves from left to right or from right to left.

[0097] In one embodiment, the mounting frame 1 includes a vertical support rod 103, the rotating shaft 204 is connected to the vertical support rod 103, the rotating shaft 204 is parallel to the detection channel, and the pitch driving mechanism 4 includes a driven gear 403 connected to the rotating shaft 204 and a driving gear 402 matched with the driven gear 403.

[0098] In this way, the transmission structure is simple, compact, small in size, strong in site adaptability of the working platform, and low in system cost. The driving gear 402 can be driven by the pitch driving motor 401, which is conducive to improving the automation degree of the device in the debugging work before detection, reducing manual participation, saving time and effort, and improving the working efficiency of detection. Specifically, the vertical support rod 103 is provided with a motor platform, and the pitch driving motor 401 is arranged on the motor platform.

[0099] In one embodiment, the mounting frame further includes a horizontal moving seat 101, and the vertical support rod 103 is arranged on the horizontal moving seat 101, and the horizontal moving seat 101 is connected with a sliding guide mechanism 5.

[0100] By arranging the sliding guide mechanism 5, the horizontal moving seat 101 can slide along the sliding guide mechanism 5, so as to adjust the positions of the detection clamp 21 and the oil brush clamp 22, realize multi-angle adjustment, ensure the positions of the detection clamp 21, the oil brush clamp 22 and the steel wire rope 100, and facilitate adjusting the camera 3 to the best shooting angle, thereby improving the quality of the image of the steel wire rope 100 and improving the detection precision.

[0101] In one embodiment, the sliding guide mechanism 5 includes a sliding groove 501 and a roller 502 arranged at the bottom of the horizontal moving seat 101, the horizontal moving seat 101 is slidably connected in the sliding groove 501 through the roller 502, and the roller 502 is provided with a self-locking structure.

[0102] In this way, the sliding connection is realized through the roller 502 and the sliding groove 501, the structure is simple, and the smooth movement of the horizontal moving seat 101 can be ensured. Since the roller 502 has a self-locking structure, the adjusted roller 502 can be self-locked and the current position can be maintained.

[0103] In one embodiment, a rotary table 40 is further included, and a plurality of mounting frames 1 are arranged on the rotary table 40 through a rotary driving mechanism 50.

[0104] In this way, the orientations of the detection clamp 21 and the oil brush clamp 22 can be adjusted together, so that the detection clamp 21 and the oil brush clamp 22 can clamp and inspect the steel wire 100 at a reasonable angle in a straight line or with various arcs, and the detection accuracy is improved.

[0105] In one embodiment, the rotating table 40 includes a base 4001 and a rotating disc 4002 arranged on the base 4001, and the plurality of mounting racks 1 are arranged on the rotating disc 4002; and the rotating driving mechanism 50 includes a gear ring 5001 connected with the rotating disc 4002 and a rotating gear 5002 for driving the gear ring 5001 to rotate.

[0106] In this way, the transmission structure is simple, compact, small in size, strong in site adaptability of the working platform, and low in system cost. The rotating gear 5002 can be driven by the rotating driving motor 5003, which is beneficial to improve the automation degree of the device in the debugging work before detection, reduce manual participation, save time and effort, and improve the working efficiency of detection.

[0107] In one embodiment, the vertical support rod 103 includes a fixed rod 1031 and an adjusting rod 1032 rotatably connected with the fixed rod 1031 through a ball hinge 1033, and the detection clamp 21 and the oil brush clamp 22 are arranged on the corresponding adjusting rod 1032.

[0108] In this way, the adjusting rod 1032 can be finely adjusted through the ball hinge 1033, so that the oil brush clamp 22 and the detection clamp 21 are more closely attached to the steel wire 100, and the detection effect is improved.

[0109] In one embodiment, the vertical support rod 103 is connected with the telescopic adjusting mechanism 60, and the telescopic adjusting mechanism 60 is suitable for driving the vertical support rod 103 to extend or retract along the length direction thereof.

[0110] In this way, the vertical support rod 103 can be adjusted in length, so that the height of the detection clamp 21 and the oil brush clamp 22 is adjusted, the height of the steel wire 100 is adapted, and the convenience of use of the device is improved.

[0111] In one embodiment, the telescopic adjusting mechanism 60 includes an electric push rod. In this way, the length of the vertical support rod 103 can be extended or shortened through electric control, so that the height of the clamp opening of the detection clamp 21 and the oil brush clamp 22 is automatically adjusted.

[0112] In one embodiment, a first electromagnet is arranged at the bottom of the base 4001, and the entire steel wire inspection device can be fixed on various bases or equipment surfaces through the first electromagnetic attraction, and various inspection angles can be achieved through the pitching driving mechanism 4, the sliding guide mechanism 5 and the telescopic adjusting mechanism 60, so that the inspection requirements of the steel wire in various states such as vertical, horizontal and with arcs can be met.

[0113] In one embodiment, the two swing arms 203 are provided with second electromagnets 6 that cooperate with each other, and the second electromagnets 6 are arranged between the rotating shafts 204 and the jaws 202.

[0114] By arranging the second electromagnets 6, the upper ends of the two swing arms 203 are provided with second electromagnets 6 that cooperate with each other. During detection, the two second electromagnets 6 are attracted by being powered, so that the two jaws 202 are close to each other and tightly closed, and the steel wire rope 100 is checked, thereby further improving the automation degree of the steel wire rope checking device.

[0115] Specifically, the second electromagnets 6 of the detection jaw 21 and the oil brush jaw 22 are synchronously actuated, so that the detection jaw 21 and the oil brush jaw 22 are synchronously opened and closed.

[0116] In one embodiment, the two swing arms 203 of the detection jaw 21 and the oil brush jaw 22 are connected with elastic reset members 7, and the elastic reset members 7 are located on the side of the rotating shaft 204 away from the jaw 202.

[0117] By arranging the elastic reset members 7, when the steel wire rope 100 is checked, the second electromagnets 6 are powered off, and the two swing arms 203 are automatically swung under the elastic force of the elastic reset members 7, so that the two jaws 202 are opened and reset, without the need for manual opening of the jaws 202, saving time and effort, and facilitating direct placement of the steel wire rope 100 for the next inspection work, improving the automation degree of the device and improving the work efficiency.

[0118] In one embodiment, the oil brush jaw 22 is provided with two, which are arranged on the two sides of the detection jaw 21. The jaws 202 of the detection jaw 21 and the oil brush jaw 22 are each provided with a plurality of cameras 3, and the plurality of cameras 3 are arranged in the circumferential direction of the jaw opening.

[0119] In this way, the number of cameras 3 can be increased, and the reasonable distribution of the cameras 3 around the circumferential direction of the steel wire rope 100 can be facilitated, so that the steel wire rope 100 can be detected in all directions. The oil brush jaws 22 are arranged in front of and behind the detection jaw 21, so that the steel wire rope 100 can be cleaned, the pictures taken by the cameras 3 can reflect the true situation of the steel wire rope 100, the interference of stains can be reduced, and the detection accuracy can be improved.

[0120] In one embodiment, the oil brush pliers 22 are provided with multiple oil brushes 30, and the oil brushes 30 gradually become thinner in the direction close to the detection pliers 21. Specifically, the single oil brush pliers 22 are provided with multiple oil brushes 30, and the multiple oil brushes 30 are of different thicknesses. Preferably, the thicknesses of the multiple oil brushes 30 gradually decrease in one direction. The oil brushes 30 gradually become thinner in the direction close to the detection pliers 21, that is, the closer to the detection pliers 21, the thinner the oil brushes 30. When two oil brush pliers 22 are provided, the two oil brush pliers 22 are respectively arranged on the left and right sides of the detection pliers 21, and the oil brushes 30 of the oil brush pliers 22 on the left side of the detection pliers 21 gradually become thinner from left to right, and the oil brushes 30 of the oil brush pliers 22 on the right side of the detection pliers 21 gradually become thinner from right to left. The thinner the oil brushes 30 means that the bristles are thinner and more dense. Figure 1 The thinner the oil brushes 30 means that the bristles are thinner and more dense.

[0121] In this way, the thick oil brushes 30 are used to clean large oil and dirt on the surface of the steel wire rope 100, and the thin oil brushes 30 are used to clean the surface of the steel wire rope 100 more carefully, so as to facilitate the detection of the steel wire rope 100 by the detector. The oil brushes 30 gradually become thinner in the direction close to the detection pliers 21, so that the steel wire rope 100 can be cleaned by the oil brush pliers 22 first and then detected by the detection pliers 21, regardless of whether the steel wire rope 100 moves from left to right or from right to left, and the oil brush pliers 22 are all used to clean large oil and dirt by the thick oil brushes 30 first and then clean more carefully by the thin oil brushes 30.

[0122] The steel wire rope inspection device provided in the embodiment has strong versatility, and can be used when the steel wire rope 100 is detected to determine whether it meets the scrap standard.

[0123] Preferably, the steel wire rope inspection device provided in the embodiment has at least three mounting frames 1, one of which is provided with the detection pliers 21, and the other two are provided with the oil brush pliers 22. Each mounting frame 1 is independently slid on the respective sliding groove 501 through the respective independent transverse moving seat 101 and the roller 502, and the three groups of sliding grooves 501 are arranged on the rotating disc 4002, so as to simplify the structure.

[0124] The present application adopts multiple combination adjustment modes to ensure that the detection clamp 21 and the oil brush clamp 22 can clamp and inspect the steel wire rope 100 at reasonable angles in the case that the steel wire rope 100 is in a straight line or has various radii. The vertical support rod 103 can vertically extend and retract through the telescopic adjustment mechanism 60 and can move horizontally through the sliding guide mechanism 5. The sliding groove 501 is arranged on the rotating disc 4002, the rotating disc 4002 is connected to the rotary drive mechanism 50, and rotation is realized. The upper part of each vertical support rod 103 is provided with a spherical hinge 1033 to automatically adjust the angle in the case that the steel wire rope 100 has a radius. An elevation drive motor 401 is independently arranged at the upper part of each vertical support rod 103 to drive the oil brush clamp 22 or the detection clamp 21 to independently rotate around the rotating shaft 204. The present application can be adjusted from multiple angles and directions to adapt to the alignment requirements of the steel wire rope 100, ensure that there is no blind area in the inspection of the steel wire rope 100, and ensure the inspection accuracy.

[0125] In one embodiment, the oil brush clamp 22 is connected with an oil supplementing device 80. The oil supplementing device 80 includes an oil tank 8001, an oil supplementing pump 8002 and an oil nozzle 8003 which are communicated with each other through an oil supplementing pipeline 8004. The oil tank 8001 and the oil supplementing pump 8002 are arranged on the rotating disc 4002 and can rotate with the rotating disc 4002. The oil nozzle 8003 is arranged on the oil brush clamp 22.

[0126] In this way, the steel wire rope 100 can be supplemented with oil after being inspected.

[0127] Further, the oil nozzle 8003 is arranged in multiple numbers and is arranged at intervals in the circumferential direction around the jaw of the oil brush clamp 22 to ensure that the oil brush 30 of the oil brush clamp 22 can be uniformly immersed in oil, so that the steel wire rope 100 can be uniformly supplemented with oil on the whole circumferential surface. When two or more oil brush clamps 22 are arranged, the oil supplementing device 80 is connected to each oil brush clamp 22. In this way, no matter in which direction the steel wire rope 100 moves, one oil brush clamp 22 can be used to remove oil and the other oil brush clamp 22 can be used to supplement oil.

[0128] According to the embodiments of the present application, the second aspect further provides a control system including an industrial computer 8, a display 9 and the steel wire rope inspection device of any one of the above technical solutions. The camera 3 is connected to the industrial computer 8 through the signal transceiver device 10, the signal antenna 20 and the industrial computer 8. The camera 3 is used to shoot the cross-sectional image of the steel wire rope 100 and send the cross-sectional image to the industrial computer 8. The display 9 is connected to the industrial computer 8 through the signal transceiver device 10 and the industrial computer 8. The display 9 is used to display the cross-sectional image received by the industrial computer 8.

[0129] Since the control system includes the steel wire rope inspection device, the control system has all the beneficial effects of the steel wire rope inspection device, which will not be described herein again. In addition, the industrial computer 8 is arranged to improve the automation degree of the inspection of the steel wire rope 100.

[0130] In one embodiment, the two swing arms 203 of the inspection pliers are each provided with a second electromagnet 6 that cooperates with the other, and the second electromagnet 6 is electrically connected to the industrial computer 8.

[0131] In this way, the power supply and power loss of the second electromagnet 6 can be controlled by the industrial computer 8, and the automatic opening and closing of the detection pliers 21 and the oil brush pliers 22 can be controlled. Through the coordinated action of each device and part, from the accurate positioning of the steel wire rope 100 to be tested in the detection preparation stage to the oil removal, detection execution, data recording and analysis in the detection process, automation can be achieved, the detection work quality is guaranteed, and the safety is high. After the device starts to work, the worker only needs to remotely monitor the detection data in real time, and the health protection of the worker is improved.

[0132] In one embodiment, the electric push rod for controlling the extension and retraction of the vertical support rod 103 is electrically connected to the industrial computer 8, so that the automation of the debugging work before the detection of the steel wire rope inspection device can be realized.

[0133] In one embodiment, the steel wire rope inspection device comprises a driving gear 402, the driving gear 402 is connected with a pitch drive motor 401, and the pitch drive motor 401 is electrically connected to the industrial computer 8.

[0134] In one embodiment, the steel wire rope inspection device comprises a rotary gear 5002, the rotary gear 5002 is connected with a rotary drive motor 5003, and the rotary drive motor 5003 is electrically connected to the industrial computer 8.

[0135] In one embodiment, the steel wire rope inspection device comprises an oil supplement pump 8002, and the oil supplement pump 8002 is electrically connected to the industrial computer 8.

[0136] In this way, the automation of the debugging work before the detection of the steel wire rope inspection device can be realized.

[0137] According to the embodiments of the present application, the third aspect also provides a steel wire rope inspection method, comprising the following steps:

[0138] Step S100, acquiring cross-sectional images of multiple angles in the circumferential direction of the steel wire rope 100;

[0139] Step S200, fitting the cross-sectional images of multiple angles at the same position into a first surface image development diagram representing the full-circumferential surface of the steel wire rope 100 at the position; along the length direction of the steel wire rope 100, multiple first surface image development diagrams are obtained by fitting multiple positions;

[0140] Step S300, fitting multiple first surface image development diagrams along the length direction of the steel wire rope 100 to obtain a second surface image development diagram representing the surface of the steel wire rope 100 along the full rope length;

[0141] Step S400, analyze the second surface image development map, and record the surface data of the steel wire rope 100;

[0142] Step S500, according to the surface data, determine the surface defects existing in the steel wire rope 100.

[0143] The steel wire rope inspection method provided by the application can characterize the broken wire development in the whole rope length range, the total number of broken wires of each strand, and other fatigue damage characteristics of the steel wire rope 100 by detecting and comparing with the initial cross-sectional development map of the steel wire rope 100 after the steel wire rope 100 works for a period of time. Direct image data is provided for subsequent steel wire fatigue damage analysis by obtaining the cross-sectional image, the first surface image development map and the second surface image development map. According to the image data, the surface data of the steel wire rope 100 is recorded, and the surface data of the steel wire rope 100 is analyzed to provide direct data support for judging whether the steel wire rope 100 reaches the scrap standard. The surface defects and the fatigue damage degree existing in the steel wire rope 100 can be accurately determined by judging the surface data, and whether the steel wire rope 100 reaches the scrap standard can be determined, so as to solve the problems of missed inspection, wrong inspection and misjudgment caused by manual inspection. The steel wire rope inspection method provided by the application can obtain the surface image of the whole rope length and the whole circumference of the steel wire rope 100, has comprehensive detection, high accuracy and good reliability, and provides safety protection for the equipment using the steel wire rope 100 and the workers.

[0144] In one embodiment, the following steps are further included:

[0145] Step S600, taking the surface data of the qualified steel wire rope 100 as the initial value, taking the surface data obtained after each inspection as the detection value, and comparing the difference between the detection value and the initial value point by point. When the difference reaches the set value, it is determined that the steel wire rope 100 is scrapped.

[0146] By adopting point-by-point comparison and analysis, the defect development of the key defect parts of the steel wire rope 100 can be mastered, and whether the steel wire rope 100 reaches the scrap standard can be accurately judged, so that the detection precision is high.

[0147] In one embodiment, the following steps are further included:

[0148] Step S700, while checking the external broken wire condition of the steel wire rope 100, the internal broken wire of the steel wire rope 100 is detected by the magnetic detection method, and the internal image development map is fitted; analyze the internal image development map, record the internal data of the steel wire rope 100, and determine the internal defects existing in the steel wire rope 100 according to the internal data.

[0149] Beneficial effects: the application can not only check the surface of the steel wire rope 100, but also detect the internal condition of the steel wire rope 100 through strong magnetic or weak magnetic detection, etc. If the broken wire in the steel wire rope 100 exceeds the standard, it is more dangerous and necessary to check than the damage on the surface of the steel wire rope 100. The steel wire data detected by the method is more accurate and comprehensive, which further improves the safety performance of the equipment with the steel wire rope 100 and ensures the personal safety of the staff.

[0150] In one embodiment, the method further comprises the following steps:

[0151] In step S800, the internal data of the qualified steel wire rope 100 is taken as the second initial value, the internal data obtained after each inspection is taken as the second detection value, the difference between the second detection value and the second initial value is compared point by point, and when the difference reaches the set value, it is determined that the steel wire rope 100 is scrapped.

[0152] Beneficial effects: by adopting point-by-point comparison and analysis, the defect development of the key defect position of the steel wire rope 100 can be mastered, whether the steel wire rope 100 reaches the scrapping standard can be accurately judged, and the detection precision is high. The combination of the judgment of the surface data and the judgment of the internal data can comprehensively judge the steel wire rope 100, and further improve the accuracy of the scrapping judgment of the steel wire rope 100.

[0153] In one embodiment, the surface data includes one or more of the rope diameter, the lay distance or the number of broken wires of the steel wire rope 100.

[0154] The surface data can reflect the fatigue failure characteristics and the fatigue failure degree of the steel wire rope 100, feedback various surface defects of the steel wire rope 100 from multiple data, comprehensively detect the defect development of the steel wire rope 100, and further improve the accuracy of judging whether the steel wire rope 100 reaches the scrapping standard.

[0155] In one embodiment, the surface defects include broken wires, rust, shrinkage or deformation.

[0156] The steel wire rope inspection method provided by the application can check surface defects such as broken wires, rust, shrinkage or deformation, comprehensively detect defects of the steel wire rope 100, and ensure the detection accuracy.

[0157] In one embodiment, the method further comprises the following steps:

[0158] Before the cross-sectional images of the steel wire rope 100 at the plurality of circumferential angles are obtained, the steel wire rope 100 is subjected to oil removal; and / or after the cross-sectional images of the steel wire rope 100 at the plurality of circumferential angles are obtained, the steel wire rope 100 is subjected to oil replenishment.

[0159] Before the cross-sectional images of the steel wire rope 100 at multiple circumferential angles are acquired, the oil removal of the steel wire rope 100 can clean the steel wire rope 100, remove the oil stains, and ensure the accuracy of the images. After the cross-sectional images of the steel wire rope 100 at multiple circumferential angles are acquired, the oiling of the steel wire rope 100 can maintain the steel wire rope 100 and prolong the service life of the steel wire rope 100.

[0160] According to the embodiments of the present application, the fourth aspect also provides a control unit comprising an acquisition module 110, a first image fitting module 120, a second image fitting module 130, an analysis module 140 and a determination module 150. The acquisition module 110 is configured to acquire cross-sectional images of the steel wire rope 100 at different circumferential angles; the first image fitting module 120 is configured to fit the cross-sectional images at multiple angles of the same position into a first surface image development diagram representing the full circumferential surface of the steel wire rope 100 at the position; along the length direction of the steel wire rope 100, multiple positions are fitted to obtain multiple first surface image development diagrams; the second image fitting module 130 is configured to fit the multiple first surface image development diagrams along the length direction of the steel wire rope 100 to obtain a second surface image development diagram representing the surface of the steel wire rope 100 along the full rope length; the analysis module 140 is configured to analyze the second surface image development diagram and record the surface data of the steel wire rope 100; and the determination module 150 is configured to determine the surface defects of the steel wire rope 100 according to the surface data.

[0161] The control unit corresponds to the steel wire rope inspection method, and thus has the same technical effects as the steel wire rope inspection method, which will not be described here.

[0162] In one embodiment, a third image fitting module is further included, which is configured to detect internal wire breakage of the steel wire rope 100 by a magnetic detection method while checking the external wire breakage of the steel wire rope 100, and fit to form an internal image development diagram; the analysis module 140 is further configured to analyze the internal image development diagram and record the internal data of the steel wire rope 100; and the determination module 150 is further configured to determine the internal defects of the steel wire rope 100 according to the internal data.

[0163] Working process:

[0164] Before detection, first place the steel wire rope 100 detection device near the steel wire rope 100 to be detected, at this time, the jaws of the oil brush clamp 22 and the detection clamp 21 are in an open state, the height of the jaws of the detection clamp 21 and the oil brush clamp 22 is adjusted by stretching and adjusting the vertical support rod 103 to adapt to the height of the steel wire rope 100 to be detected, the position of the detection clamp 21 and the oil brush clamp 22 relative to the steel wire rope 100 to be detected can also be adjusted by sliding the mounting rack 1 along the sliding guide mechanism 5, and by the rotary disc 4002, the ball hinge 1033 and the like, so that the steel wire rope 100 is detected from head to tail. By controlling the pitch driving mechanism 4, the pitch driving motor 401 drives the driving gear 402 to rotate, the driving gear 402 drives the driven gear 403 to rotate, thereby driving the vertical support rod 103 to rotate, and the jaws of the detection clamp 21 and the oil brush clamp 22 are adjusted to be coaxial with the steel wire rope 100 to be detected. When the steel wire rope 100 is adjusted into the detection channel 23, the second electromagnet 6 is energized to close, the jaws are closed, and the device is in a standby state, at this time, the steel wire rope 100 can start to move.

[0165] Start detection, the steel wire rope 100 moves, the camera 3 continuously shoots, and the detection clamp 21 continuously detects until the steel wire rope 100 passes through the detection clamp 21 and returns to the starting point.

[0166] After the images of each same section photographed by the plurality of cameras 3 are transmitted to the industrial computer 8 by wireless or wired transmission, the control unit performs image processing to provide direct image data for subsequent steel wire fatigue failure analysis. The control unit executes the above steel wire rope inspection method steps to determine whether the steel wire rope 100 meets the scrap standard.

[0167] The present application has high working efficiency, and when the steel wire rope 100 is detected, only the steel wire rope 100 needs to pass through the detection channel 23, and the camera 3 on the detection clamp 21 scans all sections of the steel wire rope 100 once, so that the detection is completed.

[0168] The control system can not only record, check and analyze the surface defects of the steel wire rope 100 through the camera 3, but also accurately measure the rope diameter and lay length, and check the internal broken wire condition of the steel wire rope 100 through various detection methods such as strong electromagnetic and weak electromagnetic. The strong and weak magnetic inspection probe 70 is arranged on the detection clamp 21, which can check the internal broken wire through magnetic detection while checking the external broken wire condition of the steel wire rope 100. After the detection data is transmitted to the analysis control system, an image development diagram can also be formed to record the internal data of the steel wire rope. The control system hardware and powerful analysis, calculation and research software are used for comprehensive analysis. The control system synchronously receives the information of the high-precision encoder of the steel wire rope 100 running mechanism, so as to accurately locate the specific position of the defect point of the steel wire rope 100, so as to comprehensively compare and analyze the same point at different time points.

[0169] The force and damage mechanism of the steel wire rope 100 are very complex. Even if the same type of steel wire rope 100 is used on the same type of equipment, the final scrap site and damage form of the steel wire rope 100 are not the same. Therefore, the use method of the steel wire rope inspection device provided in the embodiment is that after the steel wire rope 100 is newly installed, the initial detection is carried out by using the steel wire rope inspection device, and the basic data of the new steel wire rope 100 under the conditions of force and no force are recorded, mainly the rope diameter, lay length and initial surface defects (if any) of the steel wire rope 100 under the conditions of force and no force. After the steel wire rope 100 is used for a period of time, the condition of the steel wire rope 100 is detected by using the steel wire rope inspection device regularly. The system compares and analyzes the same point, and the system comprehensively analyzes the related data of the adjacent points to judge whether the scrap standard is reached, and the development of the defect of the key defect point is compared point by point, and the system research and prediction of the development trend, so as to accurately master the hidden danger point of the steel wire rope 100 and facilitate the key investigation. The steel wire rope 100 will be checked many times in the whole life cycle of the steel wire rope 100. The internal and external inspection data of the steel wire rope 100 is transmitted to the control system in real time, which is recorded, counted and summarized by the built-in program of the control system according to the time axis for comprehensive analysis. The development trend of the damage of the steel wire rope 100 is analyzed and predicted, and the preliminary analysis opinion of the reason of the abnormal condition is put forward, so as to be compared by the management personnel for further analysis and rectification.

[0170] When the detection data is continuously accumulated, the program built in the control system can deeply analyze the acquired data information, such as judging the development of broken wires in the range of 6D and 30D, the total number of broken wires of each strand, the corresponding analysis of the concentrated position of broken wires and the frequently used position, automatically forming an analysis icon to analyze the reasons for the scrap damage of the steel wire rope 100, and providing direct data support for judging whether the steel wire rope 100 reaches the scrap standard. Even based on the initial lay length and rope diameter, if the rope diameter and lay length at a certain position change to a certain extent, it can be judged that there is a broken strand defect in the rope at this position, prompting to replace it. The present application not only checks the surface of the steel wire rope, but also detects the internal condition of the steel wire rope through strong magnetic or weak magnetic detection and other methods. If the broken wire inside the steel wire rope exceeds the standard, it is more dangerous and necessary to check because it is not convenient to check the surface damage of the steel wire rope.

[0171] The present application has the following advantages:

[0172] (I) High detection accuracy. By innovatively using point-to-point comparison analysis, the development of key defect positions of the steel wire rope is mastered, and all positions in the whole rope length range of the steel wire rope are monitored.

[0173] (II) High automation degree. Through the synergistic effect of each device and each part, from the accurate positioning of the steel wire rope to be tested in the detection preparation stage to the oil removal, detection execution, data recording and analysis in the detection process, automation can be realized to ensure the quality of the detection work.

[0174] (III) High safety. After the device is started, the worker only needs to remotely monitor the detection data in real time, which improves the health protection of the worker.

[0175] (IV) Strong versatility. The device can be used for all types of steel wire rope equipment when detecting whether the steel wire rope reaches the scrap standard.

[0176] (V) High work efficiency. When the detection device is implemented, only the steel wire rope needs to pass through the detection jaw, and the camera on the detector scans all the sections of the steel wire rope once, which can complete the detection and has high work efficiency.

[0177] (VI) The system structure is simple and compact, the volume is small, the working platform has strong adaptability, and the system cost is low.

[0178] (VII) The internal non-destructive detection and reliable and systematic analysis of various running modes of steel wire ropes can be realized, and the device has good market application prospect.

[0179] Although the embodiments of the present application are described in conjunction with the drawings, various modifications and variations can be made by those skilled in the art without departing from the spirit and scope of the present application, and such modifications and variations fall within the scope defined by the appended claims.

Claims

1. A wire rope inspection device characterized by, The utility model relates to a kind of steel wire rope detection device, including: Mounting frame (1); Detection clamp (21), which is provided with camera (3) for shooting steel wire rope (100) passing through the detection clamp (21) jaw, the camera (3) is provided with multiple, and is spaced around the circumferential direction of detection channel (23); Oil brush clamp (22), which is spaced apart with the detection clamp (21) on the mounting frame (1), and the jaw of the detection clamp (21) and the oil brush clamp (22) constitutes the detection channel (23) for steel wire rope (100) to pass through; The detection clamp (21) and the oil brush clamp (22) each include two oppositely arranged clamp heads (202), the clamp head (202) is connected with swing arm (203), two swing arms (203) are rotatably connected by pivot (204), the swing arm (203) is arranged on the mounting frame (1), the swing of the swing arm (203) around the pivot (204) is suitable for driving the opening and closing movement of two clamp heads (202); The mounting frame (1) is provided with at least three, the oil brush clamp (22) is provided with at least two, the detection clamp (21) and the oil brush clamp (22) are connected by pitch driving mechanism (4) and corresponding mounting frame (1) respectively, the pitch driving mechanism (4) is suitable for driving the mounting frame (1) to pitch around the pivot (204) and swing; The mounting frame (1) includes vertical support rod (103), the pivot (204) is connected to the vertical support rod (103), the pivot (204) is parallel to the detection channel, the pitch driving mechanism (4) includes driven gear (403) connected to the pivot (204) and driving gear (402) matched with the driven gear (403); The mounting frame (1) further includes horizontal moving seat (101), the vertical support rod (103) is arranged on the horizontal moving seat (101), and the horizontal moving seat (101) is connected with sliding guide mechanism (5); It further includes rotary table (40), and a plurality of mounting frames (1) are arranged on the rotary table (40) through rotary driving mechanism (50), the rotary table (40) includes base (4001) and rotating disc (4002) arranged on the base (4001), and a plurality of mounting frames (1) are arranged on the rotating disc (4002);The rotary driving mechanism (50) includes gear ring (5001) connected with the rotating disc (4002) and rotary gear (5002) for driving the gear ring (5001) to rotate; The detection clamp (21) is provided with strong and weak magnetic inspection probe (70); The oil brush clamp (22) is connected with oil supplementing device (80), the oil supplementing device (80) includes oil tank (8001), oil supplementing pump (8002) and oil injection nozzle (8003) communicated with each other through oil supplementing pipeline (8004), the oil tank (8001) and the oil supplementing pump (8002) are arranged on the rotating disc (4002), and the oil injection nozzle (8003) is arranged on the oil brush clamp (22).

2. The wire rope inspection apparatus of claim 1, wherein, The sliding guide mechanism (5) comprises a sliding groove (501) and a roller (502) arranged at the bottom of the horizontal moving seat (101), the horizontal moving seat (101) is slidably connected in the sliding groove (501) through the roller (502), and the roller (502) is provided with a self-locking structure.

3. The wire rope inspection apparatus of claim 1, wherein, A first electromagnet is arranged below the base (4001) and is adapted to be attracted to the equipment of the steel wire rope (100) to be inspected when powered.

4. The wire rope inspection apparatus of claim 1, wherein, The vertical support rod (103) is connected with a telescopic adjusting mechanism (60), and the telescopic adjusting mechanism (60) is adapted to drive the vertical support rod (103) to telescopically extend along the length direction thereof.

5. The wire rope inspection apparatus of claim 1, wherein, The vertical support rod (103) comprises a fixed rod (1031) and an adjusting rod (1032) rotatably connected with the fixed rod (1031) through a ball hinge (1033), and the detection clamp (21) and the oil brush clamp (22) are respectively arranged on the corresponding adjusting rod (1032).

6. The wire rope inspection apparatus of claim 1, wherein, Second electromagnets (6) are arranged on the two swing arms (203) and cooperatively arranged, and the second electromagnets (6) are arranged between the rotating shafts (204) and the clamp heads (202).

7. The wire rope inspection apparatus of claim 1, wherein, Resilient return members (7) are connected to the two swing arms (203) of the detection clamp (21) and the oil brush clamp (22), and the resilient return members (7) are located on the sides of the rotating shafts (204) away from the clamp heads (202).

8. The wire rope inspection apparatus of claim 1, wherein, The oil brush clamps (22) are arranged on the two sides of the detection clamp (21), and a plurality of the camera heads (3) are arranged on the clamp heads (202) of the detection clamp (21) and the oil brush clamps (22) in a circumferential direction of the clamp openings.

9. The wire rope inspection apparatus of claim 6, wherein, A plurality of oil brushes (30) are arranged on the oil brush clamps (22) and gradually become thinner in the direction close to the detection clamp (21).

10. The wire rope inspection apparatus of claim 1, wherein, A plurality of oil injection nozzles (8003) are arranged around the clamp openings of the oil brush clamps (22) in a circumferential direction.

11. A control system characterized by, It comprises: an industrial computer (8); The steel wire rope inspection device according to any one of claims 1 to 10, the camera head (3) is connected to the industrial computer (8) through a signal transceiver (10), the camera head (3) is used for shooting the cross-sectional image of the steel wire rope (100) and sending the cross-sectional image to the industrial computer (8); a display (9) connected to the industrial computer (8) through a signal transceiver (10), the display (9) is used for displaying the cross-sectional image received by the industrial computer (8).

12. The control system of claim 11, wherein, Second electromagnets (6) are arranged on the two swing arms (203) of the detection clamp (21) and cooperatively arranged, and the second electromagnets (6) are electrically connected to the industrial computer (8).

13. The control system of claim 11, wherein, The steel wire rope inspection device comprises a driving gear (402), and the driving gear (402) is connected with a pitch driving motor (401), and the pitch driving motor (401) is electrically connected to the industrial computer (8).

14. The control system of claim 11, wherein, The steel wire rope inspection device comprises a rotating gear (5002) connected with a rotating drive motor (5003), and the rotating drive motor (5003) is electrically connected with the industrial computer (8).

15. The control system of claim 11, wherein, The steel wire rope inspection device comprises an oil supplementing pump (8002) electrically connected with the industrial computer (8).

16. A wire rope inspection method for the wire rope inspection apparatus according to any one of claims 1 to 10, characterized by, The method comprises the following steps: Obtaining cross-sectional images of the steel wire rope (100) at multiple angles around the circumference; Fitting the cross-sectional images at multiple angles of the same position into a first surface image development diagram representing the full-circumferential surface of the steel wire rope (100) at the position; along the length direction of the steel wire rope (100), multiple first surface image development diagrams are obtained by fitting the cross-sectional images at multiple positions; Fitting the multiple first surface image development diagrams along the length direction of the steel wire rope (100) to obtain a second surface image development diagram representing the surface of the steel wire rope (100) along the full rope length; Analyzing the second surface image development diagram to record the surface data of the steel wire rope (100); According to the surface data, determining the surface defects existing in the steel wire rope (100).

17. The wire rope inspection method of claim 16, wherein, The method further comprises the following steps: Taking the surface data of the qualified steel wire rope (100) as a first initial value, and taking the surface data obtained after each inspection as a first detection value, the difference between the first detection value and the first initial value is compared point by point, and when the difference reaches a set value, the steel wire rope (100) is determined to be scrapped.

18. The steel wire rope inspection method according to claim 16 or 17, characterized in that, The method further comprises the following steps: While checking the external broken wire condition of the steel wire rope (100), the internal broken wire of the steel wire rope (100) is detected by a magnetic detection method, and an internal image development diagram is fitted and formed; Analyzing the internal image development diagram to record the internal data of the steel wire rope (100); According to the internal data, determining the internal defects existing in the steel wire rope (100).

19. The wire rope inspection method of claim 18, wherein, The method further comprises the following steps: Taking the internal data of the qualified steel wire rope (100) as a second initial value, and taking the internal data obtained after each inspection as a second detection value, the difference between the second detection value and the second initial value is compared point by point, and when the difference reaches a set value, the steel wire rope (100) is determined to be scrapped.

20. The steel wire rope inspection method of claim 16 or 17, wherein, The surface data includes one or more of the rope diameter, the lay distance, or the number of broken wires of the steel wire rope (100).

21. The wire rope inspection method of claim 16 or 17, wherein, The surface defects include broken wires, rust, reduced diameter, or deformities.

22. The steel wire rope inspection method of claim 16 or 17, wherein, The method further comprises the following steps: Before the step of obtaining the cross-sectional images of the steel wire rope (100) at multiple angles around the circumference, the steel wire rope (100) is subjected to oil removal; and / or after the step of obtaining the cross-sectional images of the steel wire rope (100) at multiple angles around the circumference, the steel wire rope (100) is subjected to oil supplementing.

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