A device and method for nondestructive testing of high-speed running hoisting steel wire ropes

Abstract

The application discloses a kind of high-speed running lifting steel wire rope nondestructive testing device and method, device includes shell, at least two excitation intervals of at least 3 groups of annular electromagnet are arranged in shell along the direction of steel wire rope movement interval, realize the saturated excitation of high-speed running steel wire rope;Magnetic flux leakage field signal acquisition transmission component is arranged between every two groups of annular electromagnet by roller floating support component;Guide wheel component is arranged in the outside of shell and is arranged in front and back along the direction of steel wire rope movement, to clamp steel wire rope.The detection device of the application can realize the saturated excitation of high-speed running steel wire rope, reduce the fluctuation of lift-off value, facilitate the detection of damage signal by subsequent magnetic sensor, and has good reliability and stability.

Description

Technical Field

[0001] This invention patent relates to the field of non-destructive testing of hoisting wire ropes, specifically to a non-destructive testing device and method for high-speed hoisting wire ropes. Background Technology

[0002] Non-destructive testing (NDT) of steel wire ropes involves exploring the relationship between damage and signals using physicochemical methods such as acoustics, optics, electricity, and radiation, without damaging the rope's structure or performance. This allows for qualitative and quantitative estimation of the damage's location and extent, providing a basis for determining load-bearing capacity, service life, and replacement necessity. Representative NDT methods for steel wire ropes include acoustic, mechanical, radiation, current, optical, eddy current, ultrasonic, vibration, acoustic emission, and magnetic testing. However, the first four methods are difficult to apply in practice due to drawbacks such as susceptibility to interference, weak and difficult-to-record signals, expensive and cost-effective instruments, and poor testing performance. The high-carbon steel and high-permeability material and special structure of steel wire ropes make magnetic flux leakage testing feasible and a recognized mature and stable NDT method in the industry.

[0003] Since the first wire rope flaw detector was introduced to the market, electromagnetic non-destructive testing technology for wire ropes has been continuously developed. In practical applications, strong magnetic detection technology is mostly used. Before testing, the wire rope to be tested must be magnetized to saturation. The main detection elements include Hall effect sensors, induction coils, and fluxgate magnetometers. However, the following are some of the main problems that still exist:

[0004] 1. Existing research and equipment focus on damage to wire ropes during low-speed operation. However, in actual working conditions, high-speed operation is inevitable. As speed increases, many complex electromagnetic phenomena and signal distortion caused by dynamic magnetization become apparent, making single-stage excitation leakage flux detection insufficient for leakage flux sensors. When performing leakage flux detection on wire ropes during high-speed operation, the following three problems exist: First, the orderly arrangement of magnetic domains under external magnetic field excitation during magnetization is affected by magnetization intensity and time; insufficient excitation at high speeds affects leakage flux signal detection. Second, the eddy current effect generated by the wire rope cutting magnetic lines of force in the magnetic field is opposite to the applied magnetic field, affecting the establishment of the wire rope's saturated magnetic field. Third, as the wire rope's operating speed increases, the large fluctuations in lift-off value severely impact leakage flux signal detection.

[0005] 2. Strong magnetic field testing often requires the detection sensor to be as close as possible to the surface of the wire rope and maintain a constant distance, and is limited by the detection speed. When the running speed of the wire rope increases, the lift-off value fluctuates greatly, which seriously affects the leakage magnetic signal. The single excitation mode of the wire rope leads to a lack of expression of damage characteristics by different morphological signals.

[0006] 3. When using leakage magnetic field theory for wire rope defect detection, single sensors produce only a single signal, making multi-dimensional signal detection difficult and hindering the accurate characterization of damage morphology. Most detection equipment using permanent magnet excitation suffers from installation difficulties and limited flexibility due to the inherent magnetic field of the permanent magnet itself, resulting in unadjustable excitation source strength. Summary of the Invention

[0007] The technical problem this invention aims to solve is to overcome the shortcomings of existing technologies and provide a novel non-destructive testing device for high-speed lifting wire ropes. This device achieves superposition of the magnetic fields between the two stages of the testing device, reducing the influence of eddy currents and time effects, thus saturating the high-speed wire rope with excitation and improving testing accuracy. The device has a simple structure and uses electromagnet excitation, avoiding the installation difficulties caused by the strong attraction of permanent magnet excitation. The floating roller support component follows the slight movement of the high-speed wire rope, reducing large fluctuations in the lifting distance, resulting in good reliability and stability. Multi-dimensional signals are collected through an xyz three-axis array magnetic sensor, which can effectively characterize the damage morphology.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0009] A non-destructive testing device for high-speed hoisting wire ropes includes:

[0010] The outer casing has at least two excitation zones consisting of at least three sets of annular electromagnets spaced apart along the direction of movement of the wire rope, so as to achieve saturated excitation of the high-speed wire rope.

[0011] The leakage magnetic field signal acquisition and transmission component is set between every two sets of the annular electromagnets via a roller floating support component.

[0012] The guide wheel assembly is located on the outside of the housing and arranged in front and behind along the direction of movement of the wire rope to clamp the wire rope.

[0013] The outer casing includes an upper shell, a lower shell, a hinge, a baffle, and a latch. The hinge and the latch are used together to connect the upper shell and the lower shell. The inner sides of the upper shell and the lower shell are respectively provided with baffles for limiting the axial position of the annular electromagnet. The baffles are arranged between the multi-stage excitation components to prevent the multi-stage excitation components from moving axially.

[0014] The roller floating support assembly includes: a base, a spring, a roller bracket, and a roller, wherein,

[0015] The base is secured between the two baffles. The base has a first arc-shaped mounting surface, which is a semi-circular curved surface concentric with the diameter of the steel wire rope. A through hole is provided on the first arc-shaped mounting surface.

[0016] The bottom of the roller bracket passes through the through hole via a spring guide post, and a roller is mounted on the upper part of the roller bracket; a spring is coaxially sleeved outside the spring guide post and located between the arc-shaped mounting surface and the roller bracket;

[0017] The leakage magnetic field signal acquisition and transmission component includes: a bushing, a leakage magnetic field sensor array, and a signal transmission unit;

[0018] The upper surface of the bushing has a second arc-shaped mounting surface, which is a semi-circular curved surface concentric with the diameter of the steel wire rope. The leakage magnetic field sensor array is mounted on the second arc-shaped mounting surface. The bottom two sides of the bushing are respectively provided with protrusions, and the roller bracket is provided with a slot that cooperates with and is fixed to the protrusions. The bushing is fixed between the two roller brackets by friction between the protrusions on both sides of the bottom and the slot.

[0019] The roller floating support assembly can reduce the impact of large fluctuations in lift-off value on leakage magnetic signal when the wire rope running speed increases.

[0020] Each set of ring electromagnets includes two semi-ring electromagnets, namely an upper semi-ring electromagnet and a lower semi-ring electromagnet, wherein the upper semi-ring electromagnet is installed in the upper housing and the lower semi-ring electromagnet is installed in the lower housing.

[0021] Each semi-circular electromagnet consists of a semi-circular iron core and a coil. The coil is wound radially around the inner and outer surfaces of the semi-circular iron core, and an axial excitation magnetic field is formed by passing an electric current through it.

[0022] The distance between each pair of ring electromagnets is equal to the radius of the ring electromagnet.

[0023] The distance between the inner surface of each annular electromagnet and the surface of the steel wire rope being tested is 1-1.5 mm.

[0024] The bottom of the spring guide column is connected to an anti-loosening nut via a thread. The support height of the roller floating support assembly can be adjusted by the anti-loosening nut to accommodate the detection of steel wire ropes of different diameters.

[0025] This invention further discloses a non-destructive testing method for high-speed hoisting wire ropes, based on the aforementioned non-destructive testing device for high-speed hoisting wire ropes.

[0026] The high-speed running wire rope passes through the detection device from the side away from the roller floating support assembly. It is magnetized in the middle of the first two-stage excitation component, and then magnetized a second time in the middle of the second two-stage excitation component. By superimposing the two magnetic fields, the problem of insufficient excitation caused by time issues and eddy current effects when the wire rope is running at high speed can be solved.

[0027] The lift-off value requirements for wire ropes of different diameters can be met by changing different bushings;

[0028] In the leakage magnetic field signal acquisition and transmission component, the circularly arranged array of leakage magnetic field sensors includes three columns of leakage magnetic field sensors for detecting the leakage magnetic field in the xyz triaxial direction. The leakage magnetic field signal can be transmitted through the circuit of the signal transmission unit and finally transmitted to an external computer for offline signal processing. Beneficial effects

[0029] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art:

[0030] First, this invention achieves saturated excitation of high-speed running wire rope by providing at least two excitation intervals consisting of at least three sets of annular electromagnets; it enables the superposition of magnetic fields between the two stages of the detection device to achieve high-speed operation and enhance the saturated excitation of the wire rope, thereby improving detection accuracy.

[0031] Second, the present invention has a simple structure and uses an electromagnet excitation method, which can avoid the problem of installation difficulties caused by the strong attraction when using permanent magnet excitation.

[0032] Third, the roller floating support assembly of this invention follows the slight floating of the high-speed steel wire rope, reducing large fluctuations in the lifting distance, and has good reliability and stability;

[0033] Fourth. This invention uses a three-axis array magnetic sensor to collect multi-dimensional signals, which can well characterize the damage morphology. Attached Figure Description

[0034] The technical solution of the present invention will be further described below with reference to the accompanying drawings:

[0035] Figure 1 This is a perspective view of the detection device of the present invention;

[0036] The components include: 1. Upper housing; 2. Leakage magnetic sensor array; 3. Bushing; 4. Hinge; 5. Semi-annular iron core; 6. Coil; 7. Guide wheel; 8. Baffle; 9. Lower housing; 10. Buckle; 11. Spring; 12. Spring guide post; 13. Slot; 14. Protrusion; 15. Anti-loosening nut; 16. Roller bracket;

[0037] Figure 2 This is the outer casing of the detection device of the present invention;

[0038] Figure 3 This is a schematic diagram of the multi-stage excitation assembly structure of the detection device of the present invention;

[0039] Figure 4 This is a schematic diagram of the lower part of the steel wire rope roller floating support assembly of the detection device of the present invention (the upper part is the same).

[0040] 17. Casters; 18. Base;

[0041] Figure 5 This is a partial structural diagram of the leakage magnetic field signal acquisition and transmission component of the detection device of the present invention;

[0042] 19. Hollow column.

[0043] Figure 6 It is a simulation cloud map of a single-stage excitation of a high-speed lifting wire rope;

[0044] Figure 7 It is a simulation cloud map of multi-stage excitation of high-speed hoisting wire rope;

[0045] Figure 8 This is a comparison chart showing the change of multi-stage excitation intensity over time when the wire rope is running at a speed of 6m / s. Detailed Implementation

[0046] The present invention will be further described in detail below with reference to specific embodiments.

[0047] like Figures 1 to 5 As shown, the high-speed lifting wire rope non-destructive testing device of the present invention includes a roller floating support assembly, a multi-stage electromagnetic excitation assembly, a leakage magnetic field signal acquisition and transmission assembly, a guide wheel assembly, and a housing. The leakage magnetic field signal acquisition and transmission assembly collects the leakage magnetic field signal of the wire rope and sends it to an external computer for offline signal analysis and processing. The multi-stage excitation assembly provides an excitation source for the wire rope. The roller floating support assembly ensures that the lifting distance of the leakage magnetic field sensor remains constant during the operation of the high-speed wire rope. The guide wheel assembly and the housing can maintain stable testing.

[0048] This invention enables the superposition of magnetic fields between the two stages of the detection device, achieving saturated excitation of the high-speed steel wire rope and thus improving detection accuracy. The device has a simple structure and uses electromagnet excitation, which avoids the installation difficulties caused by the strong attraction when using permanent magnet excitation. The roller floating support component follows the slight floating of the high-speed steel wire rope, resulting in good reliability and stability.

[0049] To achieve the above objectives, the present invention provides a multi-stage electromagnetic excitation assembly, such as... Figure 3 As shown, the electromagnet includes at least 3 groups, each group of electromagnets includes an upper electromagnet and a lower electromagnet, the spacing between each group of electromagnets is equal to the radius of the semi-circular annular electromagnet, and the distance between the inner surface of the upper or lower electromagnet and the surface of the steel wire rope being measured is 1-1.5mm.

[0050] As a further improvement of the present invention, the two excitation intervals composed of the three sets of electromagnets thereby sequentially obtain two superimposed regions of excitation intensity of the same size;

[0051] Among them, the upper and lower electromagnets of the three sets of electromagnets are all magnetized along the axial direction. The excitation intensity of the upper and lower electromagnets is adjusted by the number of coil turns and the magnitude of the current passing through them, which can adapt to the excitation of steel wire ropes of different diameters within a certain range.

[0052] The roller floating support assembly, such as Figure 4 As shown, it includes:

[0053] The base 18, spring 11, roller bracket 16, and roller 17, wherein,

[0054] The base 18 is secured between the two baffles 8. The base 18 has a first arc-shaped mounting surface, which is a semi-circular curved surface that passes through the diameter of the steel wire rope. A through hole is provided on the first arc-shaped mounting surface.

[0055] The bottom of the roller bracket 16 passes through the through hole via a spring guide post 12, and a roller 17 is mounted on the upper part of the roller bracket 16.

[0056] Spring 11 is coaxially sleeved outside the spring guide post 12 and is located between the arc-shaped mounting surface and the roller bracket 16;

[0057] The leakage magnetic field signal acquisition and transmission component includes: a bushing 3, a leakage magnetic field sensor array 2, and a signal transmission unit.

[0058] The upper surface of the bushing 3 has a second arc-shaped mounting surface, which is a semi-circular curved surface concentric with the diameter of the steel wire rope. The leakage magnetic field sensor array 2 is mounted on the second arc-shaped mounting surface. The bottom two sides of the bushing 3 are respectively provided with protrusions 14. The roller bracket 16 is provided with a slot 13 that cooperates with and is fixed to the protrusions 14. The bushing 3 is fixed between the two roller brackets 16 by friction between the protrusions 14 on both sides of the bottom and the slot 13.

[0059] The roller floating support assembly can reduce the impact of large fluctuations in lift-off value on leakage magnetic signal when the wire rope running speed increases.

[0060] The leakage magnetic field signal acquisition and transmission component, such as Figure 5 As shown, it includes a bushing 3, a magnetic flux leakage sensor array 2, and a signal transmission unit. The bushing 3 is disposed inside the roller floating support assembly, and the magnetic flux leakage sensor array 2 is disposed on the bushing 3.

[0061] The outer shell, such as Figure 2 As shown, it includes an upper housing 1, a lower housing 9, two hinges 4 fastened to the upper housing 1 and the lower housing 9 by screws, and a buckle 10. The upper housing 1 and the lower housing 9 can be opened and closed to facilitate the handling of the wire rope. When the detection device is running, the buckle 10 is used to lock the upper housing 1 and the lower housing 9 to prevent the upper and lower parts from separating during the operation of the device.

[0062] The guide wheel assembly includes four guide wheels 7 with brackets, which are riveted to both ends of the upper and lower housings respectively. The upper and lower guide wheels 7 work to press the high-speed steel wire rope and make it run smoothly in the detection device. The groove depth of the upper and lower guide wheels 7 can accommodate steel wire ropes of different diameters within a certain range.

[0063] The electromagnetic excitation mechanism includes six electromagnets embedded inside the outer casing and baffles 8 for fixing the electromagnets. The baffles 8 are welded inside the outer casing to restrict the radial degree of freedom of the electromagnets. The electromagnets include a semi-circular iron core 5 and a coil 6. The coil 6 is wound radially around the inner and outer surfaces of the semi-circular iron core 5 and a current is passed through it to form an axial excitation magnetic field. The spacing between each stage is the radius of the semi-circular ring, forming a Helmholtz coil-like structure. The uniform magnetic field generated is more conducive to the excitation of the wire rope.

[0064] The roller floating support assembly includes two bases 18, eight rollers 17, a roller bracket 16, a spring 11, and a protrusion 14. The base 18, which fits against the inner side of the outer shell, has a rectangular surface, and its inner surface is a curved surface with a cross-section concentric with the diameter of the steel wire rope. The bottom of the roller bracket 16 passes through the through hole via a spring guide post, and rollers are installed on the upper part of the roller bracket.

[0065] The spring is coaxially sleeved outside the spring guide post and is located between the arc-shaped mounting surface and the roller bracket;

[0066] To facilitate the floating and even force distribution of the rollers 17 in close contact with the high-speed running wire rope, they are arranged at a 45-degree arc along the semi-circular inner curved surface section; the entire roller bracket can float up and down relative to the base via spring guide columns and springs.

[0067] The bottom of the spring guide column is connected to an anti-loosening nut via a thread. The support height of the roller floating support assembly can be adjusted by the anti-loosening nut to accommodate the detection of steel wire ropes of different diameters.

[0068] In the roller floating support assembly, the roller is slidably connected to the spring guide column 12 via the roller bracket 16, allowing the roller to float and be guided between the spring 11 and the wire rope. At the same time, the inner side of the roller bracket 16 has a slot 13, and the slot 13 on the bushing 3 is connected to the protrusion 14, which is arranged in the middle of the four roller brackets 16.

[0069] The upper and lower bases 18 of the roller floating support assembly are locked inside the upper and lower shells of the outer casing and arranged between the two stages of the multi-stage excitation assembly. The high-speed running wire rope passes through the detection device from the side away from the roller floating support assembly. It is magnetized in the middle of the first two-stage excitation component and then magnetized a second time in the middle of the second two-stage excitation component. By superimposing the two magnetic fields, the problem of insufficient excitation caused by time and eddy current effect when the wire rope is running at high speed can be solved.

[0070] Leakage magnetic field signal acquisition and transmission components, such as Figure 5 As shown, the system includes an array of magnetic flux leakage sensors 2 arranged circumferentially, a signal transmission unit, bushings 3, and slots 13. The bushings 3 slide into the protrusions 14 on the roller support 16 of the follower component through the four slots 13 on both sides. The system is installed in the middle of the roller floating support assembly. Different bushings 3 can be replaced to meet the lifting value requirements of steel wire ropes of different diameters. The array of magnetic flux leakage sensors 2 arranged circumferentially includes three rows of magnetic flux leakage sensors that detect the magnetic flux leakage of the xyz triaxial axes. The received magnetic flux leakage signals are transmitted to an external computer for offline signal processing through the hollow column 19.

[0071] Figure 6 It is a simulation cloud map of a single-stage excitation of a high-speed lifting wire rope;

[0072] Figure 7 It is a simulation cloud map of multi-stage excitation of high-speed hoisting wire rope;

[0073] Figure 8 This is a comparison chart of the change in single (multi) stage excitation intensity over time when the wire rope is running at a speed of 6m / s.

[0074] In theoretical analysis, the eddy currents and time effects generated when the hoisting wire rope runs at high speeds affect the magnetization of the magnetizer, thus impacting the detection of leakage flux signals. Multi-stage excitation can effectively improve this problem. To verify the feasibility of multi-stage excitation, such as... Figure 6 and Figure 7 Simulations were performed on the excitation intensity cloud maps of single-stage and multi-stage magnetization under a hoisting wire rope operating at a speed of 6 m / s. The magnetic field distribution in the hoisting wire rope was basically consistent, only the magnetic field intensity was enhanced. Figure 8 This is a comparison chart of the excitation intensity of single (multi) stages over time at a wire rope running speed of 6 m / s. Comparing the excitation effects of single-stage and multi-stage structures, the maximum magnetic field strength in the wire rope under multi-stage excitation is 0.1910 T, while the maximum magnetic field strength under single-stage excitation is 0.1072 T. Multi-stage excitation is nearly twice that of single-stage excitation, which clearly shows the feasibility of multi-stage excitation.

[0075] The above are merely specific application examples of the present invention and do not constitute any limitation on the scope of protection of the present invention. All technical solutions formed by equivalent transformations or substitutions fall within the scope of protection of the present invention.

Claims

1. A non-destructive testing device for high speed running hoisting wire ropes, characterized in that include: The outer casing has at least two excitation zones consisting of at least three sets of annular electromagnets spaced apart along the direction of movement of the wire rope, so as to achieve saturated excitation of the high-speed wire rope. The leakage magnetic field signal acquisition and transmission component is set between every two sets of the annular electromagnets via a roller floating support component. A guide wheel assembly is disposed on the outside of the housing and arranged in front and behind along the direction of movement of the wire rope to clamp the wire rope; The outer casing includes an upper casing, a lower casing, a hinge, a baffle, and a latch. The hinge and the latch are used together to connect the upper casing and the lower casing. The inner sides of the upper casing and the lower casing are respectively provided with baffles for limiting the axial position of the annular electromagnet. The baffles are arranged between the multi-stage excitation components to prevent the multi-stage excitation components from moving axially. The roller floating support assembly includes: a base, a spring, a roller bracket, and a roller, wherein, The base is secured between the two baffles. The base has a first arc-shaped mounting surface, which is a semi-circular curved surface concentric with the diameter of the steel wire rope. A through hole is provided on the first arc-shaped mounting surface. The bottom of the roller bracket passes through the through hole via a spring guide post, and a roller is mounted on the upper part of the roller bracket; a spring is coaxially sleeved outside the spring guide post and located between the arc-shaped mounting surface and the roller bracket; The leakage magnetic field signal acquisition and transmission component includes: a bushing, a leakage magnetic field sensor array, and a signal transmission unit; The upper surface of the bushing has a second arc-shaped mounting surface, which is a semi-circular curved surface concentric with the diameter of the steel wire rope. The leakage magnetic field sensor array is mounted on the second arc-shaped mounting surface. The bottom two sides of the bushing are respectively provided with protrusions, and the roller bracket is provided with a slot that cooperates with and is fixed to the protrusions. The bushing is fixed between the two roller brackets by friction between the protrusions on both sides of the bottom and the slot. The roller floating support assembly can reduce the impact of large fluctuations in lift-off value on leakage magnetic signal when the wire rope running speed increases.

2. The non-destructive testing device for high-speed hoisting wire ropes according to claim 1, characterized in that, Each set of ring electromagnets includes two semi-ring electromagnets, namely an upper semi-ring electromagnet and a lower semi-ring electromagnet, wherein the upper semi-ring electromagnet is installed in the upper housing and the lower semi-ring electromagnet is installed in the lower housing. Each semi-circular electromagnet consists of a semi-circular iron core and a coil. The coil is wound radially around the inner and outer surfaces of the semi-circular iron core, and an axial excitation magnetic field is formed by passing an electric current through it.

3. The non-destructive testing device for high speed running hoisting wire rope according to claim 1, characterized in that, The distance between each pair of ring electromagnets is equal to the radius of the ring electromagnet.

4. The high speed run hoisting wire rope non-destructive testing device according to claim 1, characterized in that, The distance between the inner surface of each annular electromagnet and the surface of the steel wire rope being tested is 1-1.5 mm.

5. The non-destructive testing device for high-speed hoisting wire ropes according to claim 1, characterized in that, The bottom of the spring guide column is connected to an anti-loosening nut via a thread. The support height of the roller floating support assembly can be adjusted by the anti-loosening nut to accommodate the detection of steel wire ropes of different diameters.

6. A method for non-destructive testing of high-speed hoisting wire ropes, based on the non-destructive testing device for high-speed hoisting wire ropes as described in any one of claims 1 to 5, characterized in that, The high-speed running wire rope passes through the detection device from the side away from the roller floating support assembly. It is magnetized in the middle of the first two-stage excitation assembly, and then magnetized a second time in the middle of the second two-stage excitation assembly. By superimposing the two magnetic fields, the problem of insufficient excitation caused by time issues and eddy current effects when the wire rope is running at high speed can be solved. The lift-off value requirements for wire ropes of different diameters can be met by changing different bushings; In the leakage magnetic field signal acquisition and transmission component, the circularly arranged array of leakage magnetic field sensors includes three columns of leakage magnetic field sensors for detecting the leakage magnetic field in the xyz triaxial direction. The leakage magnetic field signal can be transmitted through the circuit of the signal transmission unit and finally transmitted to an external computer for offline signal processing.

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