Nondestructive testing system for mine steel wire rope
By designing a non-destructive testing system for steel ropes for mines, the problem that the existing technology cannot accurately detect wire rope defects is solved, comprehensive inspection and early warning of the quality of steel ropes is achieved, and safety and resource utilization efficiency are improved.
Patent Information
- Application Number
- CN202510212940.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-02-26
- Publication Date
- 2025-03-28
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
Existing wire rope detection technology cannot accurately detect various defects of wire rope, resulting in safety hazards and waste of resources.
A non-destructive detection system for steel wire ropes for mining is designed, including a wire rope characteristic data acquisition module, an appearance data acquisition module, a damage data analysis module and a quality evaluation module. By collecting and analyzing the damage number, working environment data, laser point cloud map and appearance image data of the wire rope, the damage coefficient is calculated and the warning instructions are executed.
A comprehensive inspection of the quality of wire ropes has been achieved, the accuracy and visualization of the inspection have been improved, and safety hazards and resource waste have been reduced.
Smart Images
Figure CN119715568A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of wire rope detection, in particular to a nondestructive detection system for wire ropes used in mines. Background Art
[0002] Wire ropes are widely used in mining, lifting, cableway, port, ocean and other industries. Since used wire ropes generally have defects such as broken wires, wear, rust, deformation, etc., their defects and carrying capacity are directly related to the safety of on-site personnel, equipment, and hoisted objects. For a long time, my country has adopted manual visual inspection and regular mandatory scrapping to ensure safe production. This approach cannot accurately detect various defects of wire ropes, which will not only cause safety hazards, but also cause the wire ropes that are still useful to be scrapped prematurely, resulting in huge waste; However, existing wire rope defect detection methods include electromagnetic detection, magnetic particle detection, and ultrasonic detection. The use of a single-channel inspection probe is limited in detection authenticity and cannot reflect the accurate defect status. At the same time, the visualization degree of diameter detection is low, and it cannot fully reflect the overall defects of the wire rope. Summary of the invention
[0003] 1. Technical issues to be resolved In view of the deficiencies in the prior art, the present invention provides a non-destructive testing system for steel wire ropes for mining, which has the advantages of testing the quality of steel wire ropes and solves the above-mentioned technical problems.
[0004] (II) Technical solution To achieve the above object, the present invention provides the following technical solutions: a nondestructive testing system for steel wire ropes for mining, comprising a steel wire rope characteristic data acquisition module, a steel wire rope appearance data acquisition module, a steel wire rope damage data analysis module and a steel wire rope quality assessment module; The wire rope characteristic data acquisition module includes a wire rope flaw detection data acquisition unit and a wire rope working environment data acquisition unit. The wire rope flaw detection data acquisition unit is used to collect the number of damages of each lay length of the wire rope, and the wire rope working environment data acquisition unit is used to collect the working environment data of the wire rope. The wire rope characteristic data acquisition module sends the collected number of damages of each lay length of the wire rope and the working environment data of the wire rope to the wire rope damage data analysis module; The wire rope appearance data acquisition module includes a wire rope laser point cloud data acquisition unit and a wire rope appearance image data acquisition unit. The wire rope laser point cloud data acquisition unit is used to collect the distances of a plurality of points on the outer surface of the wire rope to form a laser point cloud atlas. The wire rope appearance image data acquisition unit is used to collect a plurality of wire rope appearance image data and obtain a wire rope appearance image data set. The wire rope appearance data acquisition module sends the collected laser point cloud atlas and wire rope appearance image data set to the wire rope damage data analysis module. The wire rope damage data analysis module includes a working damage analysis unit and an appearance damage analysis unit, wherein the working damage analysis unit obtains a first damage coefficient by comprehensive calculation based on the working environment data of the wire rope and the number of damages of each lay length of the wire rope, and the appearance damage analysis unit obtains a second damage coefficient by comprehensive calculation based on the laser point cloud atlas and the wire rope appearance image data set; The wire rope quality assessment module obtains a comprehensive damage coefficient of the wire rope based on a comprehensive calculation of the first damage coefficient and the second damage coefficient, and executes an early warning instruction based on the comprehensive damage coefficient.
[0005] As a preferred technical solution of the present invention, the wire rope flaw detection data acquisition unit is used to collect the specific expression of the number of damages of each lay length of the wire rope as follows: in, represents the damage set of the lay length, Respectively represent the number of damages within the first lay length of the current wire rope, , No. The number of damages within a lay length, , No. The number of damages within a lay length.
[0006] As a preferred technical solution of the present invention, the specific expression of the working environment data of the wire rope collected by the wire rope working environment data collection unit is as follows: in, Indicates the first vibration intensity value in the working environment of the wire rope. , No. The vibration intensity value, , No. The vibration intensity value, Respectively represent the first light intensity value in the wire rope working environment, , No. Light intensity values, , No. Light intensity values, Respectively represent the first dust intensity value in the working environment of the wire rope, , No. Dust intensity values, , No. Dust intensity value, A dataset representing the working environment of a wire rope.
[0007] As a preferred technical solution of the present invention, the specific expression of the distance of several points on the outer surface of the wire rope collected by the wire rope laser point cloud data acquisition unit to form a laser point cloud atlas is as follows: in, They represent the laser point set around the first sampling point of the wire rope, 、Wire Rope The laser point set around the sampling points, 、Wire Rope The laser point set around the sampling points, Represents the laser point cloud atlas, and the wire rope The laser point set around the sampling point The specific expression is as follows: in, Respectively represent the wire rope The coordinates of the first sampling point in the periphery of the sampling points, , No. The coordinates of the sampling points, , No. The coordinates of the sampling points.
[0008] As a preferred technical solution of the present invention, the wire rope appearance image data acquisition unit acquires a plurality of wire rope appearance image data, and obtains a specific expression of the wire rope appearance image data set as follows: in, represents the wire rope appearance image dataset, Indicates the appearance image data within the first lay length of the current wire rope. 、Current wire rope Appearance image data within the twist length, 、Current wire rope Appearance image data within the lay length, among which the current wire rope Appearance image data within the lay length The specific expression is as follows: in, Indicates the wire rope The average value of the damaged area of the surface coating taken from multiple angles within a lay length. Indicates the coating area of the wire rope surface.
[0009] As a preferred technical solution of the present invention, the specific steps of the working damage analysis unit comprehensively calculating the first damage coefficient based on the working environment data of the wire rope and the damage number of each lay length of the wire rope are as follows: Step A1: Wire rope-based working environment dataset Get the comprehensive risk factor of the working environment ; Step A2: Lay Length-Based Damage Set The largest one among them is taken as the lay length damage coefficient ; Step A3: Based on the comprehensive risk factor of the working environment in step A1 and the lay length damage factor in step A2 The first damage coefficient is obtained by comprehensive calculation, and the specific expression is as follows: in, represents the first damage coefficient.
[0010] As a preferred technical solution of the present invention, the comprehensive risk coefficient of the working environment in step A1 is The specific expression is as follows: in, Indicates the working environment of the wire rope The vibration intensity value, Indicates the working environment of the wire rope Light intensity values, Indicates the working environment of the wire rope Dust intensity value, Indicates the safety value of vibration intensity in the working environment of the wire rope. Indicates the safety value of light intensity in the wire rope working environment. Indicates the safety value of sand and dust intensity in the working environment of the wire rope. It means sum; The lay length damage coefficient in step A2 The expression is as follows: in, represents the damage set of the lay length, The damage set representing the lay length The maximum value in .
[0011] As a preferred technical solution of the present invention, the specific expression of the second damage coefficient obtained by the surface damage analysis unit based on the laser point cloud atlas and the wire rope appearance image data set is as follows: in, represents the second damage coefficient, Indicates the wire rope The laser point set around the sampling point Middle The distance between the coordinates of the sampling points and the axis of the wire rope, Indicates the wire rope radius, Indicates The laser point set around the sampling point The value with the smallest distance from the axis of the wire rope. Indicated in The minimum distance between the laser points around the sampling points is Represents a dataset of wire rope appearance images The largest value in .
[0012] As a preferred technical solution of the present invention, the steel wire rope quality assessment module calculates the steel wire rope comprehensive damage coefficient based on the first damage coefficient and the second damage coefficient to obtain the specific expression as follows: in, represents the first damage coefficient, represents the second damage coefficient, represents the weight coefficients that sum to 1, Represents the comprehensive damage coefficient of wire rope.
[0013] As a preferred technical solution of the present invention, the warning instruction is specifically: When the comprehensive damage factor of the wire rope >When the wire rope reaches the safety threshold, an early warning will be issued; When the comprehensive damage factor of the wire rope ≤Wire rope safety threshold, no warning will be issued.
[0014] Compared with the prior art, the present invention provides a non-destructive testing system for steel wire ropes for mining, which has the following beneficial effects: The present invention obtains a first damage coefficient by collecting working environment data of the wire rope and the number of damages of each lay pitch of the wire rope, and comprehensively calculates the first damage coefficient based on the working environment data of the wire rope and the number of damages of each lay pitch of the wire rope, and collects a laser point cloud atlas and a wire rope appearance image data set, and then comprehensively calculates the second damage coefficient based on the laser point cloud atlas and the wire rope appearance image data set, obtains a comprehensive damage coefficient of the wire rope based on the first damage coefficient and the second damage coefficient, and executes an early warning instruction based on the comprehensive damage coefficient. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1 Schematic diagram of the system framework of the present invention. DETAILED DESCRIPTION
[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0017] See also Figure 1 , a nondestructive testing system for wire ropes used in mines, including a wire rope characteristic data acquisition module, a wire rope appearance data acquisition module, a wire rope damage data analysis module and a wire rope quality assessment module; The wire rope characteristic data acquisition module includes a wire rope flaw detection data acquisition unit and a wire rope working environment data acquisition unit. The wire rope flaw detection data acquisition unit is used to collect the number of damages of each lay length of the wire rope, and the wire rope working environment data acquisition unit is used to collect the working environment data of the wire rope. The wire rope characteristic data acquisition module sends the collected number of damages of each lay length of the wire rope and the working environment data of the wire rope to the wire rope damage data analysis module. The specific expression of the wire rope flaw detection data acquisition unit for collecting the number of damages of each lay length of the wire rope is as follows: in, represents the damage set of the lay length, Respectively represent the number of damages within the first lay length of the current wire rope, , No. The number of damages within a lay length, , No. The number of damages within a lay length can be directly obtained through the flaw detection instrument. The specific expression of the working environment data of the wire rope collected by the wire rope working environment data acquisition unit is as follows: in, Indicates the first vibration intensity value in the working environment of the wire rope. , No. The vibration intensity value, , No. The vibration intensity value, Respectively represent the first light intensity value in the wire rope working environment, , No. Light intensity values, , No. Light intensity values, Respectively represent the first dust intensity value in the working environment of the wire rope, , No. Dust intensity values, , No. Dust intensity value, Represents the working environment dataset of the wire rope; The wire rope appearance data acquisition module includes a wire rope laser point cloud data acquisition unit and a wire rope appearance image data acquisition unit. The wire rope laser point cloud data acquisition unit is used to collect the distances of several points on the outer surface of the wire rope to form a laser point cloud atlas. The wire rope appearance image data acquisition unit is used to collect several wire rope appearance image data and obtain a wire rope appearance image data set. The wire rope appearance data acquisition module sends the collected laser point cloud atlas and wire rope appearance image data set to the wire rope damage data analysis module. The specific expression of the distances of several points on the outer surface of the wire rope collected by the wire rope laser point cloud data acquisition unit to form a laser point cloud atlas is as follows: in, They represent the laser point set around the first sampling point of the wire rope, 、Wire Rope The laser point set around the sampling points, 、Wire Rope The laser point set around the sampling points, Represents the laser point cloud atlas, and the wire rope The laser point set around the sampling point The specific expression is as follows: in, Respectively represent the wire rope The coordinates of the first sampling point in the periphery of the sampling points, , No. The coordinates of the sampling points, , No. The wire rope appearance image data acquisition unit acquires a number of wire rope appearance image data, and obtains the specific expression of the wire rope appearance image data set as follows: in, represents the wire rope appearance image dataset, Indicates the appearance image data within the first lay length of the current wire rope. 、Current wire rope Appearance image data within the twist length, 、Current wire rope Appearance image data within the lay length, among which the current wire rope Appearance image data within the lay length The specific expression is as follows: in, Indicates the wire rope The average value of the damaged area of the surface coating taken from multiple angles within a lay length. Indicates the coating area of the wire rope surface; The wire rope damage data analysis module includes a working damage analysis unit and an appearance damage analysis unit. The working damage analysis unit obtains the first damage coefficient by comprehensive calculation based on the working environment data of the wire rope and the damage number of each lay length of the wire rope. The specific steps are as follows: Step A1: Wire rope-based working environment dataset Get the comprehensive risk factor of the working environment , the comprehensive risk factor of the working environment in step A1 The specific expression is as follows: in, Indicates the working environment of the wire rope The vibration intensity value, Indicates the working environment of the wire rope Light intensity values, Indicates the working environment of the wire rope Dust intensity value, Indicates the safety value of vibration intensity in the working environment of the wire rope. Indicates the safety value of light intensity in the wire rope working environment. Indicates the safety value of sand and dust intensity in the working environment of the wire rope. It means sum; Step A2: Lay Length-Based Damage Set The largest one among them is taken as the lay length damage coefficient , the lay length damage coefficient in step A2 The expression is as follows: in, represents the damage set of the lay length, The damage set representing the lay length The maximum value in ; Step A3: Based on the comprehensive risk factor of the working environment in step A1 and the lay length damage factor in step A2 The first damage coefficient is obtained by comprehensive calculation, and the specific expression is as follows: in, represents the first damage coefficient; The surface damage analysis unit calculates the second damage coefficient based on the laser point cloud atlas and the wire rope appearance image data set. The specific expression is as follows: in, represents the second damage coefficient, Indicates the wire rope The laser point set around the sampling point Middle The distance between the coordinates of the sampling points and the axis of the wire rope, Indicates the wire rope radius, Indicates The laser point set around the sampling point The value with the smallest distance from the axis of the wire rope. Indicated in The minimum distance between the laser points around the sampling points is Represents a dataset of wire rope appearance images The largest value among The periphery of the sampling point The specific expression of the distance between the coordinates of the sampling points and the axis of the wire rope is: , in essence, the axis position of the wire rope is set as the origin during the point cloud sampling process, that is, The periphery of each sampling point is the cross section of the wire rope. After collecting the point cloud data, the point cloud data can be directly output and all Displayed in color, in the generated point cloud model, the closer the value is, The lighter the color of the point, the darker the color, so that the wear point can be clearly displayed, which is convenient for the staff to repair or adjust the workpiece at the wear point; The wire rope quality assessment module calculates the comprehensive damage coefficient of the wire rope based on the first damage coefficient and the second damage coefficient, and executes the warning instruction based on the comprehensive damage coefficient. The specific expression of the comprehensive damage coefficient of the wire rope obtained by the wire rope quality assessment module based on the first damage coefficient and the second damage coefficient is as follows: in, represents the first damage coefficient, represents the second damage coefficient, represents the weight coefficients that sum to 1, Indicates the comprehensive damage coefficient of the wire rope. The specific warning instructions are: When the comprehensive damage factor of the wire rope >When the wire rope reaches the safety threshold, an early warning will be issued; When the comprehensive damage factor of the wire rope ≤Wire rope safety threshold, no warning will be issued.
[0018] Example: The diameter of the wire rope in this embodiment is 24.5 mm. mm, , and there are 6 strands with 19 strands per strand. The recorded data is shown in Table 1 below; Table 1
[0019] The first damage factor , the second damage coefficient , ≤Wire rope safety threshold = 7.68, no warning is issued at this time; Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A non-destructive testing system for steel wire ropes used in mines, characterized in that: It includes wire rope characteristic data acquisition module, wire rope appearance data acquisition module, wire rope damage data analysis module and wire rope quality assessment module; The wire rope characteristic data acquisition module includes a wire rope flaw detection data acquisition unit and a wire rope working environment data acquisition unit. The wire rope flaw detection data acquisition unit is used to collect the number of damages of each lay length of the wire rope, and the wire rope working environment data acquisition unit is used to collect the working environment data of the wire rope. The wire rope characteristic data acquisition module sends the collected number of damages of each lay length of the wire rope and the working environment data of the wire rope to the wire rope damage data analysis module; The wire rope appearance data acquisition module includes a wire rope laser point cloud data acquisition unit and a wire rope appearance image data acquisition unit. The wire rope laser point cloud data acquisition unit is used to collect the distances of a plurality of points on the outer surface of the wire rope to form a laser point cloud atlas. The wire rope appearance image data acquisition unit is used to collect a plurality of wire rope appearance image data and obtain a wire rope appearance image data set. The wire rope appearance data acquisition module sends the collected laser point cloud atlas and wire rope appearance image data set to the wire rope damage data analysis module. The wire rope damage data analysis module includes a working damage analysis unit and an appearance damage analysis unit, wherein the working damage analysis unit obtains a first damage coefficient by comprehensive calculation based on the working environment data of the wire rope and the number of damages of each lay length of the wire rope, and the appearance damage analysis unit obtains a second damage coefficient by comprehensive calculation based on the laser point cloud atlas and the wire rope appearance image data set; The wire rope quality assessment module obtains a comprehensive damage coefficient of the wire rope based on a comprehensive calculation of the first damage coefficient and the second damage coefficient, and executes an early warning instruction based on the comprehensive damage coefficient.
2. A nondestructive testing system for steel wire ropes for mining according to claim 1, characterized in that: The specific expression of the wire rope flaw detection data acquisition unit for collecting the number of damages of each lay length of the wire rope is as follows: in, represents the damage set of the lay length, Respectively represent the number of damages within the first lay length of the current wire rope, , No. The number of damages within a lay length, , No. The number of damages within a lay length.
3. A nondestructive testing system for steel wire ropes for mining according to claim 2, characterized in that: The specific expression for collecting the working environment data of the wire rope by the wire rope working environment data collection unit is as follows: in, Indicates the first vibration intensity value in the working environment of the wire rope. , No. The vibration intensity value, , No. The vibration intensity value, Respectively represent the first light intensity value in the wire rope working environment, , No. Light intensity values, , No. Light intensity values, Respectively represent the first dust intensity value in the working environment of the wire rope, , No. Dust intensity values, , No. Dust intensity value, A dataset representing the working environment of a wire rope.
4. A nondestructive testing system for steel wire ropes for mining according to claim 3, characterized in that: The specific expression of the distance of several points on the outer surface of the wire rope collected by the wire rope laser point cloud data acquisition unit to form a laser point cloud atlas is as follows: in, They represent the laser point set around the first sampling point of the wire rope, 、Wire Rope The laser point set around the sampling points, 、Wire Rope The laser point set around the sampling points, Represents the laser point cloud atlas, and the wire rope The laser point set around the sampling point The specific expression is as follows: in, Respectively represent the wire rope The coordinates of the first sampling point in the periphery of the sampling points, , No. The coordinates of the sampling points, , No. The coordinates of the sampling points.
5. A nondestructive testing system for steel wire ropes for mining according to claim 4, characterized in that: The wire rope appearance image data acquisition unit acquires a plurality of wire rope appearance image data, and obtains a specific expression of the wire rope appearance image data set as follows: in, represents the wire rope appearance image dataset, Indicates the appearance image data within the first lay length of the current wire rope. 、Current wire rope Appearance image data within the twist length, 、Current wire rope Appearance image data within the lay length, among which the current wire rope Appearance image data within the lay length The specific expression is as follows: in, Indicates the wire rope The average value of the damaged area of the surface coating taken from multiple angles within a lay length. Indicates the coating area of the wire rope surface.
6. A nondestructive testing system for steel wire ropes for mining according to claim 5, characterized in that: The specific steps of the working damage analysis unit comprehensively calculating the first damage coefficient based on the working environment data of the wire rope and the damage number of each lay length of the wire rope are as follows: Step A1: Wire rope-based working environment dataset Get the comprehensive risk factor of the working environment ; Step A2: Lay Length-Based Damage Set The largest one among them is taken as the lay length damage coefficient ; Step A3: Based on the comprehensive risk factor of the working environment in step A1 and the lay length damage factor in step A2 The first damage coefficient is obtained by comprehensive calculation, and the specific expression is as follows: in, represents the first damage coefficient.
7. A nondestructive testing system for steel wire ropes for mining according to claim 6, characterized in that: The comprehensive risk factor of the working environment in step A1 The specific expression is as follows: in, Indicates the working environment of the wire rope The vibration intensity value, Indicates the working environment of the wire rope Light intensity values, Indicates the working environment of the wire rope Dust intensity value, Indicates the safety value of vibration intensity in the working environment of the wire rope. Indicates the safety value of light intensity in the wire rope working environment. Indicates the safety value of sand and dust intensity in the working environment of the wire rope. It means sum; The lay length damage coefficient in step A2 The expression is as follows: in, represents the damage set of the lay length, The damage set representing the lay length The maximum value in .
8. A nondestructive testing system for steel wire ropes used in mines according to claim 7, characterized in that: The specific expression of the second damage coefficient obtained by the surface damage analysis unit based on the laser point cloud atlas and the wire rope appearance image data set is as follows: in, represents the second damage coefficient, Indicates the wire rope The laser point set around the sampling point Middle The distance between the coordinates of the sampling points and the axis of the wire rope, Indicates the wire rope radius, Indicates The laser point set around the sampling point The value with the smallest distance from the axis of the wire rope. Indicated in The minimum distance between the laser points around the sampling points is Represents a dataset of wire rope appearance images The largest value in .
9. A nondestructive testing system for steel wire ropes for mining according to claim 8, characterized in that: The specific expression of the comprehensive damage coefficient of the wire rope obtained by the wire rope quality assessment module based on the first damage coefficient and the second damage coefficient is as follows: in, represents the first damage coefficient, represents the second damage coefficient, represents the weight coefficients that sum to 1, Represents the comprehensive damage coefficient of wire rope.
10. A nondestructive testing system for steel wire ropes for mining according to claim 9, characterized in that: The warning instructions are specifically: When the comprehensive damage factor of the wire rope >When the wire rope reaches the safety threshold, an early warning will be issued; When the comprehensive damage factor of the wire rope ≤Wire rope safety threshold, no warning will be issued.