A method for detecting broken wires of a steel wire rope suitable for a multi-row pulley block

Abstract

A kind of method suitable for multiple rows of pulley block steel wire rope broken wire detection, this method is based on a kind of signal acquisition and processing device suitable for multiple rows of pulley block steel wire rope broken wire detection, the signal acquisition and processing device electromagnet, hall module, permanent magnet, power module, signal acquisition and processing module.Electromagnet and hall module cooperate to form a circular structure, form closed round hole in the middle, steel wire rope passes through round hole, permanent magnet is fixed on the surface of hall module, power module is connected with electromagnet, permanent magnet respectively, hall module is connected with signal acquisition and processing module.The application of a kind of method suitable for multiple rows of pulley block steel wire rope broken wire detection greatly improves the collection efficiency of hoistway steel wire rope broken wire signal, simple and convenient operation.

Description

Technical Field

[0001] This invention relates to the field of wire rope breakage detection technology, and in particular to a signal acquisition and processing device suitable for wire rope breakage detection in multi-row pulley blocks. Background Technology

[0002] In the operation of a ship lift, the wire rope plays a crucial role. During the ascent and descent of the ship's hold, the wire rope bears immense tensile stress, and its mechanical properties directly affect the safe operation of the lift. For large lifting machinery like a ship lift, accidents are absolutely unacceptable, as the consequences could be extremely catastrophic. Therefore, personnel must regularly inspect the mechanical properties of the wire rope, with broken wire detection being particularly important. In the past, the main method for broken wire detection was visual inspection. However, because the surface of the wire rope is completely covered with a thick layer of grease, the reliability of this method needs improvement. Currently, the most widely used method for wire rope broken wire detection is magnetic flux leakage detection. The conventional method for magnetic flux leakage detection involves attaching a Hall effect sensor to the surface of the wire rope being tested. This method is cumbersome and prone to magnetic flux leakage. Summary of the Invention

[0003] To address the aforementioned technical problems, this invention provides a signal acquisition and processing device suitable for detecting broken wires in multi-row pulley wire ropes. This device ensures that leakage magnetic signals can be fully acquired and processed while the wire rope is moving. Furthermore, the device is easy to assemble and disassemble and is simple to operate, making it suitable for continuous detection of multi-row pulley wire ropes.

[0004] The technical solution adopted in this invention is as follows:

[0005] A signal acquisition and processing device for detecting broken wires in multi-row pulley systems of steel wire rope includes an electromagnet, a Hall effect module, a permanent magnet, a power supply module, and a signal acquisition and processing module. The electromagnet and Hall effect module work together to form a circular structure with a closed circular hole in the center. The steel wire rope passes through this hole. The permanent magnet is fixed to the surface of the Hall effect module. The power supply module is connected to both the electromagnet and the permanent magnet. The Hall effect module is connected to the signal acquisition and processing module.

[0006] The power module is used to output a high-frequency AC constant current power supply and a constant current power supply. The high-frequency AC constant current power supply is used to provide power to the electromagnet, and the constant current power supply is used to provide power to the Hall module.

[0007] The high-frequency AC constant current power output port of the power module is connected to the electromagnet via a cable, and the connection between the cable and the electromagnet is a detachable quick connector.

[0008] The Hall module and the electromagnet mounting surface are wedge-shaped structures that cooperate with each other, serving a positioning and guiding function.

[0009] The Hall module and the electromagnet are respectively mounted on the first base plate and the second base plate;

[0010] The device also includes a first base and a second base, on which a first guide rail slider and a second guide rail slider are respectively installed; a first base plate cooperates with the first base through the first guide rail slider, and a second base plate cooperates with the second base through the second guide rail slider; the Hall module and the electromagnet move radially toward each other along the wire rope through the first and second guide rail sliders respectively.

[0011] Both the first and second bases are equipped with four traveling wheels and one guide wheel on their bottom surfaces. The guide wheel's groove is fitted with a track, the length of which is greater than the length of a row of pulleys. This ensures that the device's travel within the track covers the range of a row of pulleys, and all steel wire ropes within that range are fully inspected, enabling rapid movement and positioning of the device. The electromagnet has a cross-section with a smaller arc length than a semicircle, while the Hall effect module has a cross-section with a larger arc length than a semicircle. The smaller and larger arc structures work together to form a ring structure.

[0012] This invention provides a signal acquisition and processing device for detecting broken wires in multi-row pulley systems, which greatly improves the acquisition efficiency of broken wire signals in steel wire ropes used in ship lifts and is simple and convenient to operate. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the main mounting structure of the present invention.

[0014] Figure 2 for Figure 1 A magnified view of point A.

[0015] Figure 3 This is a side view of the mounting structure of the present invention.

[0016] Figure 4 for Figure 3 Enlarged view at point B.

[0017] Figure 5 This is a schematic diagram of the structure of the present invention.

[0018] Figure 6 This is a schematic diagram of the assembly of the electromagnet and Hall module of the present invention. Detailed Implementation

[0019] like Figures 1-6 As shown, a signal acquisition and processing device suitable for detecting broken wires in steel wire ropes of multi-row pulley blocks includes an electromagnet 3, a Hall effect module 4, a permanent magnet 5, a power supply module 6, and a signal acquisition and processing module 7. The steel wire rope 2 is located on the pulley block 1.

[0020] Electromagnet 3 and Hall module 4 work together to form a ring structure with a closed circular hole in the middle. Steel wire rope 2 passes through the circular hole, and permanent magnet 5 is fixed on the surface of Hall module 4. Power module 6 is connected to electromagnet 3 and permanent magnet 5 respectively, and Hall module 4 is connected to signal acquisition and processing module 7.

[0021] The power module 6 is used to output a high-frequency AC constant current power supply and a constant current power supply. The high-frequency AC constant current power supply is used to provide power to the electromagnet 3, and the constant current power supply is used to provide power to the Hall module 4.

[0022] The high-frequency AC constant current power output port of the power module 6 is connected to the electromagnet 3 via a cable, and the connection between the cable and the electromagnet 3 is a detachable quick connector.

[0023] The mounting surfaces of the Hall module 4 and the electromagnet 3 are wedge-shaped structures that cooperate with each other, serving as positioning and guiding functions.

[0024] The Hall module 4 and the electromagnet 3 are respectively installed on the first base plate 8 and the second base plate;

[0025] The device also includes a first base 10 and a second base, on which a first guide rail slider 9 and a second guide rail slider are respectively installed.

[0026] The first base plate 8 engages with the first base 10 via the first guide rail slider 9, and the second base plate engages with the second base via the second guide rail slider. The slider of the guide rail slider is fixed to the bottom of the base plate. A handle is installed on the base plate. Operating the handle facilitates the movement of the base plate 8 along the guide rail, ensuring that the electromagnet 3 and the Hall module 4 can be separated or joined.

[0027] from Figure 2 Looking at it from above, the power module 6 is placed on the first base plate 8. The power module 6 moves synchronously with the first base plate 8 to avoid secondary handling.

[0028] Hall module 4 and electromagnet 3 move radially toward each other along wire rope 2 via the first and second guide rail sliders, respectively.

[0029] The bottom surfaces of the first base 10 and the second base are each equipped with four traveling wheels 11 and one guide wheel 12. The wheel groove on the guide wheel 12 is fitted with the track 13, and the length of the track 13 is greater than the length of a row of pulleys.

[0030] The electromagnet 3 has a cross-section with a smaller arc length than the semicircular arc length, and the Hall module 4 has a cross-section with a larger arc length than the semicircular arc length. The smaller arc structure and the larger arc structure work together to form a ring structure.

[0031] The contact surface between Hall module 4 and electromagnet 3 is made smaller than the cross-section through the center of the circle, increasing the coverage area of ​​Hall module 4 and improving detection accuracy. Simultaneously, the interaction force between the steel wire rope and the detection device during movement has a smaller impact on the contact surface, ensuring device stability. A closed circular hole is formed in the middle of the assembly of electromagnet 3 and Hall module 4, through which the steel wire rope 2 passes. The diameter of the steel wire rope 2 is smaller than the diameter of the circular hole.

[0032] The Hall module 4 includes multiple magnetic Hall sensors SS94A2D, which are embedded in an arc structure and evenly arranged along the circle, facilitating overall movement. It does not require individual and repeated attachment to the steel wire rope being tested, resulting in high detection accuracy and reduced labor.

[0033] The signal acquisition and processing module 7 includes an amplifier LM741, an A / D converter ADC0809, a microcontroller AT89C51, a digital tube, and a buzzer; the Hall module 4 is connected to the amplifier LM741, the amplifier LM741 is connected to the A / D converter ADC0809, the A / D converter ADC0809 is connected to the microcontroller AT89C51, and the microcontroller AT89C51 is connected to the digital tube and the buzzer respectively.

[0034] The leakage magnetic field signal is sensed by Hall module 4, forming a voltage signal output. The A / D converter ADC0809 performs analog-to-digital conversion on the transmitted analog voltage signal, then the data is processed by the AT89C51 microcontroller, and the data is sent to the digital tube for display. At the same time, the buzzer sounds an alarm. Detecting wire breakage by detecting the leakage magnetic field of the wire rope is simple, intelligent, reliable, and eliminates some human interference.

[0035] A method for detecting broken wires in steel wire ropes with multiple pulley blocks is provided. A power module 6 outputs a high-frequency AC constant current power supply to energize an electromagnet 3. The energized electromagnet 3 automatically attracts a permanent magnet 5. When the steel wire rope 2 moves, the power module 6 outputs a constant current power supply to energize a Hall effect module 4. A signal acquisition and processing module 7 acquires and processes the broken wire signal of the steel wire rope 2. After signal acquisition and processing, the electromagnet 3 is de-energized. The electromagnet 3 and the Hall effect module 4 are then moved along the guide rail sliders towards each other until they are completely disengaged. The two bases are then moved along the guide rail to the next steel wire rope, and the signal acquisition is repeated.

[0036] Working principle:

[0037] The two bases move along track 13, and the electromagnet 3 and Hall module 4 reach the steel wire rope 2 to be tested. The electromagnet 3 and Hall module 4 are moved closer to each other along the guide rail slider 9. The steel wire rope 2 is located in the closed circular hole formed between the electromagnet 3 and Hall module 4. The power module 6 outputs high-frequency AC constant current power to power the electromagnet 3. After the electromagnet 3 acquires magnetism, it is tightly attracted to the permanent magnet 5 on the surface of the Hall module 4. When the steel wire rope moves, the power module 6 outputs constant current power to power the Hall module 4. The Hall module 4 collects the wire breakage signal and sends it to the signal acquisition and processing module 7.

[0038] After the signal acquisition is completed, the electromagnet 3 is de-energized, the Hall module 4 is disengaged from the electromagnet 3, and the electromagnet 3 and the Hall module 4 are moved towards each other along the guide rail slider until they are completely disengaged. The two bases are moved along the track 13, and the electromagnet 3 and the Hall module 4 reach the next wire rope to be tested 2, and the broken wire signal of the next wire rope is acquired and processed.

Claims

1. A method for detecting broken wires in wire ropes of multi-row pulley blocks, characterized in that, This method is based on a signal acquisition and processing device suitable for detecting broken wires in steel wire ropes of multi-row pulley blocks. The signal acquisition and processing device includes: an electromagnet (3), a Hall module (4), a permanent magnet (5), a power supply module (6), and a signal acquisition and processing module (7). The electromagnet (3) and the Hall module (4) cooperate to form a ring structure with a closed circular hole in the middle. The steel wire rope (2) passes through the circular hole. The permanent magnet (5) is fixed on the surface of the Hall module (4). The power supply module (6) is connected to the electromagnet (3) and the permanent magnet (5) respectively. The Hall module (4) is connected to the signal acquisition and processing module (7). The power module (6) outputs a high-frequency AC constant current power supply to power the electromagnet (3). When the electromagnet (3) is powered on, it automatically attracts the permanent magnet (5). When the wire rope (2) moves, the power module (6) outputs a constant current power supply to power the Hall module (4). The signal acquisition and processing module (7) acquires and processes the wire rope (2) breakage signal. After the signal acquisition and processing is completed, the electromagnet (3) is de-energized. The electromagnet (3) and the Hall module (4) are operated to move towards each other along the guide rail slider until they are completely separated. The two bases are moved along the guide rail to the next wire rope and the signal acquisition is repeated.

2. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 1, characterized in that: The power module (6) is used to output a high-frequency AC constant current power supply and a constant current power supply. The high-frequency AC constant current power supply is used to provide power to the electromagnet (3), and the constant current power supply is used to provide power to the Hall module (4).

3. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 1, characterized in that: The high-frequency AC constant current power output port of the power module (6) is connected to the electromagnet (3) via a cable, and the connection between the cable and the electromagnet (3) is a detachable quick connector.

4. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 1, characterized in that: The mounting surfaces of the Hall module (4) and the electromagnet (3) are wedge-shaped structures that cooperate with each other, which serve as positioning and guiding functions.

5. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 1, characterized in that: The Hall module (4) and electromagnet (3) are respectively installed on the first base plate (8) and the second base plate; The device also includes a first base (10) and a second base, on which a first guide rail slider (9) and a second guide rail slider are respectively installed; The first base plate (8) is engaged with the first base (10) via the first guide rail slider (9), and the second base plate is engaged with the second base via the second guide rail slider. The Hall module (4) and the electromagnet (3) move radially toward each other along the wire rope (2) via the first and second guide rail sliders, respectively.

6. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 5, characterized in that: The first base (10) and the second base are each equipped with four walking wheels (11) and one guide wheel (12). The guide wheel (12) is fitted with a track (13) and the track (13) is longer than the length of a row of pulleys.

7. The method for detecting broken wires in a multi-row pulley system wire rope according to claim 1, characterized in that: The electromagnet (3) has a cross-section with a smaller arc length than the semicircular arc length, and the Hall module (4) has a cross-section with a larger arc length than the semicircular arc length. The smaller arc structure and the larger arc structure work together to form a ring structure.

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