An online testing instrument for elevator wire ropes and its non-destructive testing system and method.

Abstract

This invention discloses an online elevator wire rope inspector and its non-destructive testing system and method. It belongs to the field of elevator equipment operation and maintenance technology. The online elevator wire rope inspector includes: a main body and a detection probe; the main body includes a main housing, inside which a main control board is installed, and an alloy cover plate is installed between the main control board and the main housing; a clamping mechanism is installed outside the main housing to fix the main housing to the traction machine steel beam; the detection probe has a single-sided open probe housing, inside which an amorphous wire sensor is installed, with the detection surface of the amorphous wire sensor facing the open surface of the probe housing; the main housing and the probe housing are connected by a metal gooseneck tube, and the main control board collects the magnetic field strength signal detected by the amorphous wire sensor. This invention uses a weak magnetic excitation sensor as the detection element, which can accurately detect wire rope defects and realize real-time monitoring and intelligent management.

Description

Technical Field

[0001] This invention relates to the field of elevator equipment operation and maintenance technology, and more specifically, to an online elevator wire rope testing instrument and its non-destructive testing system and method. Background Technology

[0002] Non-destructive testing of elevator wire ropes is a crucial step in ensuring the safety of people's lives and property, and is of great significance to the safe operation of elevators. Currently, the management of elevator wire ropes mainly relies on manual experience or judgment based on service life. However, the operating environment of each elevator is different, with variations in factors such as temperature, humidity, load weight, and maintenance conditions. This leads to a large number of wire ropes still within their service life being prematurely scrapped, while defective wire ropes continue to operate, posing safety hazards.

[0003] In the field of nondestructive testing (NDT), technologies such as ultrasonic testing and radiographic testing are widely used, but they have significant shortcomings in the inspection of elevator wire ropes. Ultrasonic testing requires a coupling agent to ensure good contact between the probe and the wire rope, but the complex operating environment of elevator wire ropes makes it difficult for the coupling agent to adhere stably, affecting the continuity and accuracy of the inspection. Simultaneously, the complexity of the internal structure of the wire rope causes ultrasonic signals to easily scatter and attenuate during propagation, making it difficult to accurately identify and analyze defect echo signals, limiting its ability to detect minute and deep defects. While radiographic testing has applications in some industrial inspection scenarios, its application in elevator wire rope inspection is subject to many limitations. Radiographic testing is harmful to human health, posing significant safety risks in the crowded elevator environment. Furthermore, radiographic testing equipment is bulky and complex to operate, requiring specialized protective measures, which not only increases inspection costs but also makes effective inspection difficult in the confined space and dynamic operating conditions of elevators.

[0004] Furthermore, current wire rope inspections generally employ offline methods, which have numerous drawbacks. Inspections are mostly conducted when equipment is shut down, making it impossible to monitor the wire rope's operational status in real time, detect potential defects under dynamic changes, and suffer from poor timeliness and high safety risks. Simultaneously, downtime inspections increase equipment downtime, reduce operating efficiency, and increase operating costs, failing to meet the actual needs for safe and efficient inspection of elevator wire ropes. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the present invention provides an online elevator wire rope inspection instrument and its non-destructive testing system and method. Based on a multi-level network architecture and using a weak magnetic excitation sensor as the detection element, it can accurately detect wire rope defects, realize real-time monitoring and intelligent management, and solve the problems of low accuracy, high cost and inability to monitor in real time of traditional detection methods. This ensures the safe operation of elevators, reduces maintenance costs and improves management efficiency.

[0006] On one hand, this invention provides an online elevator wire rope detector, comprising: a main body and a detection probe; the main body includes a hollow main housing, inside which a main control board is disposed, and an alloy cover plate is disposed between the main control board and the main housing; a clamping mechanism is disposed outside the main housing for fixing the main housing to the traction machine steel beam; the detection probe includes a probe housing with a single-sided open structure, inside which an amorphous wire sensor is disposed, the detection surface of the amorphous wire sensor facing the open surface of the probe housing; the main housing and the probe housing are connected by a metal gooseneck tube, and the main control board is electrically connected to the amorphous wire sensor via a wire for acquiring the magnetic field strength signal detected by the amorphous wire sensor, and the detection range of the amorphous wire sensor is made to cover the position of the wire rope by adjusting the angle of the metal gooseneck tube.

[0007] Furthermore, there are two amorphous wire sensors, which are arranged side by side inside the probe housing along the length of the elevator wire rope.

[0008] Furthermore, a 4G data transmission module is also provided inside the main housing. The 4G data transmission module is connected to the main control board and is used to upload the data collected by the main control board.

[0009] Furthermore, the clamping mechanism includes an upper clamping plate, a lower clamping plate, and a clamping plate shaft. The upper and lower clamping plates are rotatably connected to the clamping plate shaft. A first torsion spring is concentrically mounted on the clamping plate shaft, with its two ends abutting against the upper and lower clamping plates respectively, so that when the first torsion spring is compressed, the clamping ends of the upper and lower clamping plates separate from each other. The clamping end of the lower clamping plate is provided with a gripper. The gripper and the lower clamping plate are rotatably connected to a gripper shaft. A second torsion spring is concentrically mounted on the gripper shaft, with its two ends abutting against the gripper and the lower clamping plate respectively, so that when the second torsion spring is compressed, the upper surface of the gripper is parallel to the lower surface of the clamping end of the upper clamping plate.

[0010] Furthermore, the amorphous wire sensor includes an amorphous wire, a detection coil, a preamplifier, an analog switch, an integrator, a filter, and a resistor. One end of the amorphous wire is connected to a pulse signal source, and the other end is grounded. The detection coil is wound around the amorphous wire and connected to the input terminal of the preamplifier. The output terminal of the preamplifier is connected to the first input terminal of the analog switch. The second input terminal of the analog switch is connected to the pulse signal source. The output terminal of the analog switch is connected to the input terminal of the integrator. The output terminal of the integrator is connected to the input terminal of the filter. The resistor is connected in parallel between the input terminal of the preamplifier and the input terminal of the filter. The filter is used to output an analog signal of the magnetic field strength detected by the detection coil.

[0011] Furthermore, the alloy cover plate is made of permalloy, the main housing is made of aluminum alloy, and the metal gooseneck tube is made of nickel-titanium alloy.

[0012] On one hand, embodiments of the present invention provide an elevator non-destructive testing system including an online elevator wire rope detector, comprising at least one online elevator wire rope detector as described in any of the above-mentioned embodiments, and: a local computer running data receiving and processing software, the data receiving and processing software being used to communicate with the online elevator wire rope detector, on the one hand acquiring the magnetic field strength signal of the elevator wire rope collected by the online elevator wire rope detector, on the other hand processing the magnetic field strength signal of the elevator wire rope, and identifying defects based on the processed magnetic field strength signal, wherein the identified defects include wear, corrosion, broken wires, deformation, and changes in internal stress; and a cloud server running data receiving and management software, the data receiving and management software being used to communicate with the data receiving and processing software, receiving the magnetic field strength signal of the elevator wire rope collected by the online elevator wire rope detector and the defect information identified by the data receiving and processing software, and updating the elevator equipment operation history data.

[0013] Furthermore, the elevator non-destructive testing system also includes: a local display screen that runs display management software, which communicates with the data receiving and processing software to graphically display the processed magnetic field strength signal.

[0014] Furthermore, the elevator non-destructive testing system also includes a cloud 4G module, which is installed in the elevator machine room to enable wireless communication between the cloud server and the local computer.

[0015] On the other hand, embodiments of the present invention also provide an online non-destructive testing method for elevator wire ropes, implemented based on the aforementioned elevator non-destructive testing system. The method includes the following steps: setting at least four online elevator wire rope testing instruments along the circumference of the elevator wire rope; adjusting the positions of the online elevator wire rope testing instruments so that the vertical distance between the detection coil of the amorphous wire sensor of any of the online elevator wire rope testing instruments and the elevator wire rope is 8-12mm; extracting the magnetic field strength signal on the wire rope in real time through the amorphous wire sensor, and sending the magnetic field strength signal to the data receiving and processing software running on the local computer through the main control board of the online elevator wire rope testing instrument; processing the magnetic field strength signal and plotting the magnetic field strength change curve, and identifying defects based on the shape change of the curve; and sending the processed magnetic field strength signal and the identified defect information to the data receiving and management software running on the cloud server for storage.

[0016] Compared with the prior art, the present invention has the following advantages.

[0017] 1. This application utilizes the magnetic memory effect of metals to perform rapid non-destructive testing on defects and stress concentration areas in metal parts and structural components, requiring neither external excitation nor ultrasonic coupling media. This solves the problems of complex equipment, cumbersome operation, and high energy consumption caused by the need for excitation devices and media in traditional testing methods, achieving simple operation and low energy consumption. This allows for the miniaturization and lightweighting of the testing instrument, making it easy to carry and deploy. Furthermore, the real-time monitoring process does not require elevator shutdown, making it compatible with elevators of different speeds and rope diameters, and supporting the entire lifecycle management of the wire rope, significantly improving inspection efficiency.

[0018] 2. This application uses an amorphous wire extremely weak magnetic sensor as the sensing unit, which has a sensitivity millions of times higher than existing magnetic measurement methods. It can identify internal defects in elevator wire ropes, such as wear, corrosion, broken wires, deformation, and changes in internal stress, and provide specific information such as the nature, location, and extent of the defects. This solves the problems of low accuracy and inability to accurately identify defects in traditional detection technologies, achieving precise detection. Simultaneously, real-time data monitoring is achieved through IoT transmission. Based on the monitoring data, wire rope defect hazard warnings and expected service life assessments can be performed, avoiding excessive replacement of wire ropes, extending their service life, and, in conjunction with elevator health records, developing scientific maintenance plans, thus improving the reliability and effectiveness of the detection.

[0019] 3. This application employs non-contact testing, which does not generate radiation or electromagnetic radiation, thus solving the problems of potential harm to the human body and interference with elevator operation caused by traditional testing methods, achieving a safe testing effect. Furthermore, it is unaffected by external environmental factors such as dust and water mist, ensuring the stability of the test results.

[0020] 4. The system architecture constructed in this application is flexible, the cloud server is upgradeable, and it can adapt to the growth in the number of testing instruments and meet the needs of applications of different scales. It solves the problem that traditional testing systems are difficult to expand and adapt to diverse application scenarios, and provides good technical support and expansion space for the widespread application and future development of elevator wire rope testing.

[0021] In summary, on the one hand, this application eliminates the need for an excitation device, avoiding problems such as performance degradation, measurement instability, and periodic remagnetization associated with excitation devices during prolonged use, thus achieving lifetime maintenance-free operation and reducing maintenance costs. On the other hand, through precise testing and expected service life assessment of the wire rope, it avoids economic waste caused by excessive wire rope replacement, reduces downtime losses, and brings significant economic benefits to elevator use and maintenance. Therefore, this application can be widely promoted in the field of elevator equipment testing. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the 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 based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of an online elevator wire rope testing instrument in one embodiment.

[0024] Figure 2 The image shown is a right view of the structure of an online elevator wire rope testing instrument in this embodiment.

[0025] Figure 3 This is a schematic diagram of the clamping mechanism in the embodiment.

[0026] Figure 4 This is a cross-sectional view of the clamping mechanism in the embodiment on the BB plane.

[0027] Figure 5 This is a cross-sectional view of the clamping mechanism in the embodiment on the CC plane.

[0028] Figure 6 This is a side view of the clamping mechanism in the embodiment.

[0029] Figure 7 This is a schematic diagram of the amorphous filament sensor structure in the embodiment.

[0030] Figure 8(a) is a schematic diagram of magnetic induction lines without defects in defect detection.

[0031] Figure 8(b) is a schematic diagram of the magnetic induction lines of a defect in defect detection.

[0032] Figure 9 This is a schematic diagram of an elevator non-destructive testing system including an online elevator wire rope testing instrument, as described in the embodiment.

[0033] Figure 10 This is a schematic diagram of the data receiving process of the cloud server data receiving management software in an embodiment.

[0034] Figure 11 This is a schematic diagram of the data receiving process of the local computer data receiving and management software in the embodiment.

[0035] Figure 12 This is a schematic diagram of the defect identification process of the local computer data receiving and management software in the embodiment.

[0036] Figure 13 This is a schematic diagram of the detection interface displayed on the local large screen in the embodiment.

[0037] Figure 14 This is a schematic diagram of the broken wires in the steel wire rope and the distribution of its magnetic field strength in the embodiment.

[0038] In the diagram: 1. Amorphous wire sensor; 100. Amorphous wire; 101. Detection coil; 102. Preamplifier; 103. Analog switch; 104. Integrator; 105. Filter; 106. Resistor; 2. Main control board; 3. Alloy cover plate; 4. Metal gooseneck tube; 5. Probe housing; 6. Main housing; 7. Clamping mechanism; 701. Gripper; 702. Clamping plate shaft; 703. Upper clamping plate; 704. Lower clamping plate; 705. Gripper shaft; 706. First torsion spring; 707. Second torsion spring; 8. Wire port. Detailed Implementation

[0039] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0040] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0041] Example 1

[0042] This embodiment provides an online elevator wire rope testing instrument, such as... Figure 1As shown, it mainly includes: a main body and a detection probe. The main body includes a hollow main housing 6, inside which is a main control board 2, and an alloy cover plate 3 between the main control board 2 and the main housing 6. A clamping mechanism 7 is provided on the outside of the main housing 6 to fix the main housing 6 to the traction machine steel beam. The detection probe includes a probe housing 5 with a single-sided open structure, inside which is an amorphous wire sensor 1, with the detection surface of the amorphous wire sensor 1 facing the open surface of the probe housing 5. The main housing 6 and the probe housing 5 are connected by a metal gooseneck tube 4. The main control board 2 is electrically connected to the amorphous wire sensor 1 through wires to collect the magnetic field strength signal of the elevator steel wire rope detected by the amorphous wire sensor 1. The angle of the metal gooseneck tube 4 is adjusted so that the detection range of the amorphous wire sensor 1 covers the position of the steel wire rope.

[0043] As a preferred embodiment, such as Figure 2 As shown, in this embodiment, in order to improve the sensing accuracy of the magnetic field strength, the number of amorphous wire sensors 1 is set to two, and they are arranged side by side inside the probe housing 5 along the length of the elevator steel wire rope.

[0044] As a further preferred embodiment, in this example, a 4G data transmission module is also provided inside the main housing 6. This 4G data transmission module is connected to the main control board 2 and is used to upload data collected by the main control board 2. The 4G data transmission module enables the online elevator wire rope detector to connect to an external wireless network. The online elevator wire rope detector collects the magnetic field strength signal of the elevator wire rope, performs preliminary processing by its internal circuitry, and then transmits it to the local computer at a set rate via the 4G data transmission module. The 4G data transmission module adjusts its parameters according to the on-site network conditions to ensure stable data transmission.

[0045] like Figure 3-6 As shown, the clamping mechanism 7 in this application includes an upper clamping plate 703, a lower clamping plate 704, and a clamping plate shaft 702. The upper clamping plate 703 and the lower clamping plate 704 are rotatably connected to the clamping plate shaft 702. A first torsion spring 706 is concentrically mounted on the clamping plate shaft 702. The two ends of the first torsion spring 706 abut against the upper clamping plate 703 and the lower clamping plate 704 respectively, so as to realize that when the first torsion spring 706 is compressed, the clamping ends of the upper clamping plate 703 and the lower clamping plate 704 separate from each other. The lower clamping plate 704 has a clamping jaw 701 at its clamping end. Both the clamping jaw 701 and the lower clamping plate 704 are rotatably connected to a clamping jaw shaft 705. A second torsion spring 707 is concentrically mounted on the clamping jaw shaft 705. The two ends of the second torsion spring 707 abut against the clamping jaw 701 and the lower clamping plate 704, respectively, so that when the second torsion spring 707 is compressed, the upper surface of the clamping jaw 701 is parallel to the lower surface of the clamping end of the upper clamping plate 703. In this embodiment, three clamping jaws 701 are preferably arranged side by side to improve the clamping stability of the clamping mechanism 7.

[0046] like Figure 7As shown, the amorphous wire sensor 1 includes an amorphous wire 100, a detection coil 101, a preamplifier 102, an analog switch 103, an integrator 104, a filter 105, and a resistor 106. One end of the amorphous wire 100 is connected to a pulse signal source, and the other end is grounded. The signal output frequency of the pulse signal source is between 280 and 310 kHz. The detection coil 101 is wound around the amorphous wire 100 and connected to the input terminal of the preamplifier 102. The output terminal of the preamplifier 102 is connected to the first input terminal of the analog switch 103. The second input terminal of the analog switch 103 is connected to the pulse signal source. The output terminal of the analog switch 103 is connected to the input terminal of the integrator 104. The output terminal of the integrator 104 is connected to the input terminal of the filter 105. The resistor 106 is connected in parallel between the input terminal of the preamplifier 102 and the input terminal of the filter 105. The filter 105 is used to output an analog signal of the magnetic field strength detected by the detection coil 101.

[0047] In a preferred embodiment, the alloy cover plate 3 is made of permalloy, the main housing 6 is made of aluminum alloy, and the metal gooseneck tube 4 is made of nickel-titanium alloy. The alloy cover plate 3 is made of permalloy (magnetic permeability 10). 5 The low-frequency magnetic field of the traction machine's permanent magnet motor is attenuated (40dB attenuation for 50Hz interference), reducing time-varying magnetic field interference. The main housing 6 is made of aluminum alloy, shielding against high-frequency electromagnetic interference (60dB attenuation above 100MHz) to cope with the electromagnetic environment at the testing site. In addition, the metal gooseneck tube 4 is made of nickel-titanium alloy (which can be bent and locked 360°) to fix the detection probe in the detection range of 5-15mm from the wire rope, avoiding eddy current interference at <5mm. At the same time, wavelet algorithm is used to compensate for signal attenuation, ensuring a signal-to-noise ratio (SNR) >15dB. Even better, the detection distance range of the detection probe from the wire rope is set to 8-12mm.

[0048] This application utilizes the magnetic memory effect of metals to detect defects and stress concentration areas in metal parts and structures. The magnetic memory effect refers to the irreversible reorientation of magnetic domains with magnetostrictive properties in stress and deformation concentration areas of ferromagnetic metal parts during processing and operation, due to the combined effects of load and the Earth's magnetic field. This irreversible change in magnetic state is not only retained after the working load is removed but is also related to the maximum applied stress. This magnetic state on the surface of the metal component "memorizes" the location of microscopic defects or stress concentrations, hence the so-called magnetic memory effect. When a ferromagnetic component in a geomagnetic environment is subjected to an external load, the magnetic domains with magnetostrictive properties undergo irreversible reorientation in stress concentration areas. Fixed nodes of magnetic domains appear in these areas, generating magnetic poles and forming a demagnetizing field, thus minimizing the permeability of the ferromagnetic metal in these areas and creating a leakage magnetic field on the metal surface. The tangential component Hpx of this leakage magnetic field intensity has a maximum value, while the normal component Hpy changes sign and reaches zero. This irreversible change in magnetic state is retained even after the working load is removed.

[0049] The principle of metal magnetic memory testing is shown in Figures 8(a) and 8(b). Based on the fundamental principle of the metal magnetic memory effect, the testing instrument records the distribution of the magnetic field intensity component perpendicular to the surface of the metal component along a certain direction, thereby evaluating the stress concentration and the presence of micro-defects. It can diagnose stress concentration areas, micro-defects, and early failures and damage within ferromagnetic metal components, preventing sudden fatigue damage. This is a new testing method that has emerged in the field of nondestructive testing with the advancement and development of magnetic sensor technology.

[0050] When testing a brand-new, defect-free, 6×19 single steel wire rope with a diameter of 16mm using an amorphous wire sensor, the magnetic field strength is completely uniformly distributed along its entire length, without any obvious protrusions or depressions, as shown in Figure 8(a). However, when one or more wires of the steel wire rope are cut or pulled at any selected location, theoretically, the increased magnetic resistance at the broken wire will generate a leakage magnetic field, resulting in obvious protrusions and depressions at the corresponding locations in the amorphous wire sensor output. Furthermore, the height and width of the protrusions and depressions are closely related to the number of broken wires, as shown in Figure 8(b).

[0051] Preferably, in this embodiment, the main housing 6 adopts a box-type structure, weighs less than 0.5kg, and has dimensions of 150mm × 88.5 × 50mm. The mounting interface consists of four parallel M4 screws, distributed in dimensions of 60 × 35mm. This design balances miniaturization, lightweight, ease of installation, and ease of measurement, ensuring stable detection in different scenarios. The elevator wire rope online detector is clamped to a suitable position on the elevator mainframe steel beam in the machine room using the clamping mechanism 7, without affecting the normal operation of the elevator. The probe housing 5 is placed parallel to and close to the entire row of wire ropes at a distance of 5-15mm. Within this distance, it can be ensured that the internal amorphous wire sensor 1 can receive the magnetic field strength signal generated by the geomagnetic induction of the wire rope.

[0052] The amorphous wire sensor 1 is housed inside the probe housing 5. The main housing 6 and the probe housing 5 are connected by a metal gooseneck tube 4 (made of nickel-titanium alloy, which can be bent and locked at 360°). Ball heads (allowing 360° rotation and locking) are provided at both ends of the metal gooseneck tube 4. Considering the complex installation environment and limited space of the online elevator wire rope tester, the varying number, thickness, and spacing of different elevator wire ropes, and the rough, uneven installation surface (containing materials such as cement and steel beams), which generally prohibits drilling, two amorphous wire sensors 1 are used. This significantly reduces the size of the probe housing 5 and enhances flexibility while ensuring measurement accuracy and range. A clamping mechanism 7 is used to overcome the challenges of the complex installation environment. The amorphous wire sensor 1, serving as the data acquisition unit of the online elevator wire rope tester, is housed inside the probe housing 5. During actual testing, the metal gooseneck tube 4 is adjusted to maintain a suitable detection distance between the probe housing 5 and the tested elevator wire rope, ensuring that the probe housing 5 is parallel to the tested wire rope row, thus facilitating comprehensive and accurate data acquisition from the entire rope row. The probe housing 5 features a single-side plate structure, enabling detection of steel wire ropes from different angles, thus improving the comprehensiveness and accuracy of the inspection. It also reduces the weight of the detection module and the load on the metal flexible hose, simplifying the structure, facilitating replacement and maintenance, and reducing replacement costs. Non-contact detection reduces the risk of touching the steel wire rope, and compared to previous single-wire measurements, it can now simultaneously measure multiple steel wire ropes in a row.

[0053] Example 2

[0054] Based on Embodiment 1, this embodiment provides an elevator non-destructive testing system including an online elevator wire rope detector, comprising at least one online elevator wire rope detector as described in Embodiment 1. It also includes a local computer and a cloud server. The local computer runs data receiving and processing software that communicates with the online elevator wire rope detector. This software acquires the magnetic field strength signal of the elevator wire rope collected by the online detector and processes the signal. Based on the processed magnetic field strength signal, it identifies defects, including wear, corrosion, broken wires, deformation, and changes in internal stress. The cloud server runs data receiving and management software that communicates with the data receiving and processing software. This software receives the magnetic field strength signal of the elevator wire rope collected by the online detector and the defect information identified by the data receiving and processing software, and updates the elevator equipment's historical operating data.

[0055] In a preferred embodiment, this example uses four online elevator wire rope testing instruments to inspect the elevator wire rope from four different directions. Assuming that a brand-new, defect-free wire rope undergoes non-destructive testing, its magnetic field strength is completely uniformly distributed along its entire length, without obvious protrusions or depressions. If one or more wires of the wire rope are cut or pulled at any location, a leakage magnetic field will be generated at the broken wire due to increased magnetic resistance. Therefore, in the online elevator wire rope testing instrument, the magnetic field strength signal output by the amorphous sensor closest to the broken wire will show obvious protrusions and depressions at its corresponding location. Other sensors also show protrusions and depressions, but the amplitude is relatively small, and the height and width of the protrusions and depressions are closely related to the number of broken wires. The detected magnetic field strength signal is converted into multiple A / D signals by the main control board 2. Then, the relevant data (such as location, magnetic field strength of each magnetic sensor, etc.) are combined into a data packet and sent to the local computer through the 4G data transmission module. After data processing, defect identification and diagnosis, the computer displays the current detection results on the screen in the form of magnetic maps, curves, histograms, pie charts, etc.

[0056] In a preferred embodiment, the elevator non-destructive testing system in this example also includes a Youren Cloud 4G module, which is used to upload the data collected and identified on the local computer to the cloud server. In this application, the cloud server is an Alibaba Cloud server. The Youren Cloud 4G module is a USR-G780 v2 module. Specifically, the Youren Cloud 4G module mainly consists of a 4G module host, a SIM IoT card, and a 4G module transceiver antenna. The local computer connects to the RS485 port of the USR-G780 4G module through its network port to achieve data relay. The USR-G780 v2 4G module can be set to different communication rates to achieve efficient data transmission and processing, transmitting the test data to the Alibaba Cloud server.

[0057] This embodiment addresses the technical challenges of detecting time-varying magnetic fields from the permanent magnet motor of the elevator traction machine, the unique interference patterns of each elevator, and the significant magnetic interference at the moment of elevator start-up. It employs a dual anti-interference mechanism. Firstly, hardware shielding technology is used to address the electromagnetic interference environment. For example, the online elevator wire rope detector described in this embodiment uses a double-layer shielding system consisting of an aluminum alloy main housing 6 and a probe housing 5, plus a permalloy metal cover plate 3. Secondly, software denoising algorithms are used to improve data reliability during data processing. Specifically, Discrete Wavelet Transform (DWT) is used to decompose the magnetic field strength signal into three frequency bands (approximate component A3, detail components D1-D3), separating low-frequency interference (such as the motor's fundamental frequency) from high-frequency defect signals (broken wires corresponding to the D1-D2 frequency band). Wavelet transform is used to reconstruct the denoised signal, resulting in a defect feature retention rate exceeding 92% and a signal-to-noise ratio improvement of 15-20 dB. Subsequently, wavelet packet decomposition (WPD) is performed to extract multi-band energy features (such as the low-frequency band of 0-500Hz and the high-frequency band of 1000-2000Hz), and combined with parameters such as kurtosis and peak factor, to provide multi-dimensional feature vectors for defect classification.

[0058] In addition, for the broadband pulse interference (200ms, 100-500Hz) at the moment of elevator start-up, the interference interval is marked by wavelet time-frequency graph, the corresponding wavelet coefficients are forcibly set to zero, and morphological filtering (opening operation) is combined to remove spike noise, so as to ensure the defect identification rate during the interference period and achieve time-frequency interference suppression.

[0059] To address the challenges of complex on-site testing conditions and limited space, this application achieves a lightweight and miniaturized online elevator wire rope testing instrument while overcoming the technical difficulties posed by ambient temperature and equipment heating to the tested object.

[0060] Specifically, this application's online elevator wire rope detector removes the local processing module, retaining only data acquisition and 4G transmission functions, with the main control board and 4G data transmission module integrated into a single design. The aluminum alloy shell (thermal conductivity 237W / m·K) and the mounting channel steel form a heat conduction path, resulting in a temperature rise of <5℃ with a total power consumption of 3W (shell temperature 40℃ at an ambient temperature of 35℃). Temperature drift is eliminated (<0.1%FS) using a wavelet baseline correction algorithm. An extremely weak magnetic amorphous wire sensor 1 (accuracy 500PT, power consumption 0.5W) is employed to avoid the influence of high-power device heating.

[0061] This application addresses the technical challenge of rapidly identifying and accurately determining the various defect types in elevator traction steel wire ropes, which present numerous defect categories. It employs a high-frequency sampling and feature extraction mechanism. The sensor captures signals at a 5000Hz sampling rate, and WPD (Wide Voltage Detection) is used to extract features such as energy percentage, kurtosis, and peak factor across each frequency band. For example, broken wires exhibit high-frequency (1000-2000Hz) spike pulses with a kurtosis >5.0; wear is characterized by a low-frequency (0-500Hz) energy percentage >60% with continuous fluctuations; and broken strands show multi-frequency energy abrupt changes, a peak factor >3.5, and are accompanied by low-frequency resonance.

[0062] More preferably, this embodiment can also incorporate an intelligent classification model: constructing a 1D-CNN convolutional neural network, containing 3 convolutional layers and fully connected layers, for processing multi-dimensional feature inputs. Model input: multi-dimensional feature data, with a shape of (number of samples, time step, feature dimension). Model output: raw scores (logits) without softmax activation, with a shape of (number of samples, number of classes).

[0063] like Figure 9 As shown, in a preferred embodiment of this application, the elevator non-destructive testing system in this embodiment mainly includes an Alibaba Cloud server running data receiving and management software, a local computer running data receiving and processing software, an online elevator wire rope tester, a local display screen running display management software, and a Youyun 4G module.

[0064] In this embodiment, a wire rope defect detector is installed online in the elevator shaft in real time, operating 24 hours a day, 365 days a year. Data collected by the online wire rope detector is transmitted to a cloud server in real time, where data from multiple elevators is centrally processed. The defect type, quantity, and location of each elevator are updated continuously, and historical data for each elevator is stored in a cloud database. The system monitors the health status and trends of each elevator in real time, and takes appropriate actions based on current, historical, and trend data to ensure the safety of each elevator throughout its entire lifecycle. The specific setup is as follows.

[0065] During the installation period: high-frequency sampling (5000Hz) captures manufacturing defects (such as cold-drawn cracks in steel wire), and wavelet analysis is used to identify signal anomalies and establish an initial health record.

[0066] During operation: a health index (based on defect density and growth rate) is generated daily, the remaining lifespan is predicted using the ARIMA model, the warning threshold is set at 80% of the theoretical lifespan, and the defect location and quantity are updated in real time on the cloud.

[0067] Retirement period: Cloud storage of full lifecycle data provides wear simulation basis for the design of new steel wire ropes, forming a closed loop of "detection-analysis-optimization".

[0068] Specifically, the data receiving and management software includes a port management module, a data receiving module, and a storage and management module. For example... Figure 10 The diagram illustrates the data reception process of an Alibaba Cloud server. The main process is as follows: After starting, variables are initialized, and a loop waits until 5 AM. Once the time condition is met, it checks if the current time is greater than 5 AM. If so, a sub-function is called to retrieve the port list. Next, it checks if a simple log file needs to be created. If so, the list of ports requiring data for the day is written to the log file; otherwise, the process ends. Then, it checks if the port list length is greater than 0. If so, the main loop is entered, checking if the current time is less than 11 PM. During this time period, the port list is traversed, checking if each port is still in the list. If a port is still in the list, the time is checked again. If the time meets the condition, a sub-function is called to receive and store the data for the current port until the port list has been traversed. If the current time is not less than 11 PM or the port is not in the list, the log file is recorded, and the process exits. The entire process, through loops and conditional checks, controls data reception and storage operations on specified ports within a specific time period, while simultaneously recording relevant logs for later review.

[0069] Furthermore, the data receiving and processing software includes a data receiving module, a data cleaning module, a defect detection module, and a result storage and management module. The local computer operates at specific time intervals, acquiring data from the Alibaba Cloud server. After cleaning and extraction, the data is processed in segments and defects are detected. The results are then written into the elevator archive. A simplified flowchart of the main program of the local computer's receiving and processing software can be found here. Figure 11 After initializing variables, the process enters a loop and waits until a specific time is reached. Once the time condition is met, the current date is retrieved. Next, it checks if a subdirectory named after the date exists. If not, it creates the subdirectory; if it exists, a sub-function is called to copy data files from Alibaba Cloud to that subdirectory. A list of files in the current date directory is retrieved, and each file in the list is processed: it checks if the file is still in the current date directory's file list; if not, it is logged. If the file exists, a sub-function is called to clean and extract the current data file and save it as a .mat file. Useful data (data) is extracted from the current .mat file. The data is split into segments with 28000 as the boundary, and it is checked if the split data_process is still within the data range: if not, it is logged. If it is within the data range, a sub-function is called to perform fault detection on the current data. If the detection results meet the conditions, the number of faults, fault rate, etc., are written to the elevator archive file. If the conditions are not met, it is logged.

[0070] Data processing is performed using Python 3 as the programming tool, currently employing a time-domain processing method. Data is segmented into 25,000-byte segments, and defects are accurately identified by identifying peaks and troughs, performing parameter statistics, and matching with typical defect and interference signal curves. In the long term, wavelet analysis, artificial intelligence, and machine learning technologies will be combined to achieve industry-leading detection from qualitative to quantitative analysis. The defect detection subroutine flowchart is shown below. Figure 12 The main process includes the following steps: First, extract the useful data `data` from the current `.mat` file. Second, perform data segmentation and processing: divide the useful data `data` into segments of 28000 bytes each, forming the segmented `data_process`. Determine if the current `data_process` is still within the data processing range: if not, log the results in the log file and return the detection results (number of defects, detection rate, etc.) to the main program, then terminate the subroutine. Third, initialize the variables: initialize variables: `v_off=2800`, `peak_valley_min=1300`, `data_temp=[]`, `peaks_temp=[]`, `valleys_temp=[]`, `index_0=0`. Then, perform data segmentation and matching: divide the current 28000-byte data segment into `data2_temp`. Determine if the current `data2_temp` is still within the data processing range: if not, return to continue segmenting `data_process`. If within the range, then find the peaks and valleys: Find the "peaks_temp" within the current data segment, and remove peaks using a set amplitude to generate a new "peaks" list. Find the "valleys_temp" within the current data segment, and remove valleys using a set amplitude to generate a new "valleys" list. Finally, perform matching and removal processing. Match the "valleys" list with a typical defect curve and a set similarity to generate a new "valleys" list. Use a typical interference curve and a set similarity to remove valleys from the "valleys" list to generate a new "valleys" list. Match the "peaks" list with a typical defect curve and a set similarity to generate a new "peaks" list. Use a typical interference curve and a set similarity to remove valleys from the "peaks" list to generate a new "peaks" list. If there is still data to process, repeat the above steps to process the next data segment. The entire process uses loops and conditional judgments to segment the data, find peaks and valleys, match typical curves, and remove interference. Finally, the processed detection results are returned to the main program, and relevant log files are recorded.

[0071] The local computer operates from 9:00 AM to 11:50 PM daily, retrieving the day's data files from the Alibaba Cloud server. After cleaning and extraction, the data is processed in segments, and the defect detection algorithm is invoked to write the results into the elevator archive.

[0072] Furthermore, such as Figure 13 The image shows the detection interface displayed on the local large screen in this embodiment. The upper left corner is a data display area for historical monitoring of a specific elevator, showing information such as the number of defects and test time. Different elevators can be switched by setting a path. The upper right corner is a data statistics area for all tested elevators, such as the total number of monitored elevators, the number of broken wires, and the number of rusted elevators. The lower part of the image is a real-time monitoring curve display area for elevators, showing the magnetic signal curve of the steel wire rope detection for a specific elevator. The real-time magnetic signal curves of different elevators can be displayed using the data import button. Figure 14 A schematic diagram of the magnetic field strength distribution under the condition of a broken wire in the steel wire rope in this embodiment is provided. As shown in the figure, the magnetic field strength signal curves around the four steel wire ropes are given. The vertical axis represents the magnetic field strength, and the horizontal axis represents the position of the elevator steel wire rope. According to the signal curves in the figure, the steel wire rope represented by the yellow dashed line has very obvious peak changes in the range of 680-880. Therefore, it can be determined that there is a defect in this steel wire rope. Based on the specific shape of the curve, the type of defect can be further determined.

[0073] As a preferred embodiment, the elevator non-destructive testing system may also include a local display screen, which runs display management software and communicates with data receiving software to graphically display the processed magnetic field strength data.

[0074] In this embodiment, a Youyun 4G module is installed in the elevator machine room. Addressing the technical challenges of weak signal strength and high-temperature environments in elevator machine rooms, this embodiment employs a dual-environmental interference resistance design. Firstly, it utilizes MIMO dual-antenna technology: reducing the bit error rate by 40% in weak signal environments (<-110dBm) and supporting automatic gain control (AGC) and diversity reception (activated when <-105dBm). Secondly, it adapts to various scenarios; in extreme environments with very weak signals in the elevator machine room (rooftop), it can switch to NB-IoT mode (coverage enhancement of 20dB), employing a TCP long connection + heartbeat mechanism, with reconnection in <5 seconds after network disconnection. Temperature self-adaptation: A built-in PT100 sensor dynamically adjusts power consumption via the SPI interface, achieving 99.5% transmission stability from -30℃ to 70℃.

[0075] Example 3

[0076] This invention also provides an online non-destructive testing method for elevator wire ropes, based on the elevator non-destructive testing system in Embodiment 2. The method includes the following steps.

[0077] At least four online elevator wire rope detectors are installed along the circumference of the elevator wire rope. The positions of these detectors are adjusted so that the vertical distance between the detection coil of the amorphous wire sensor on any of the detectors and the elevator wire rope is 8-12mm. This distance range is the optimal detection distance determined through extensive experimental verification. It ensures that the sensor effectively detects the magnetic field strength signal of the wire rope while avoiding signal distortion or weakness caused by excessively close or distant distances, thus laying the foundation for accurate defect identification.

[0078] The online elevator wire rope detector extracts the magnetic field strength signal from the wire rope in real time using amorphous wire sensors, and then transmits this signal to the data receiving and processing software running on the local computer via the main control board. Specifically, the amorphous wire sensors operate in real time, closely tracking and accurately extracting the magnetic field strength signals generated on and inside the wire rope. These sensors, with their high sensitivity, can capture subtle changes in the magnetic field caused by defects in the wire rope during operation. Subsequently, the main control board of the online elevator wire rope detector responds quickly, performing preliminary integration and encoding of the collected magnetic field strength signals to ensure signal integrity and stability during transmission. The processed magnetic field strength signal is then immediately sent to the data receiving and processing software running on the local computer, establishing an efficient information transmission link between the testing site and the data processing center, achieving seamless data integration.

[0079] The data receiving and processing software processes the magnetic field strength signal and plots a magnetic field strength variation curve, identifying defects based on the curve's shape. Specifically, upon receiving the magnetic field strength data, the software, running on the local computer, immediately activates a specialized data processing algorithm module. First, it performs a series of preprocessing operations, including filtering and noise reduction, to remove interference signals and extract effective magnetic field strength information relevant to the actual state of the wire rope. Next, based on a preset data fitting model and curve plotting algorithm, it transforms the processed data into an intuitive magnetic field strength variation curve, clearly showing the fluctuations in magnetic field strength at different locations on the wire rope. Through in-depth analysis of the curve's shape changes, and using a built-in defect feature recognition algorithm, it compares and matches the curve with known defect feature templates to accurately identify whether the wire rope has defects such as broken wires, wear, or corrosion, as well as the specific location and severity of these defects, providing crucial information for subsequent maintenance and repair.

[0080] The data receiving and processing software sends the processed magnetic field strength data and identified defect information to the data receiving and management software running on the cloud server for storage. Specifically, after processing the magnetic field strength data and identifying defect information, the data receiving and processing software sends these two crucial pieces of information—the processed magnetic field strength data and the identified defect information—to the data receiving and management software running on the cloud server, according to a unified data format and transmission protocol. The cloud server-side data receiving and management software is responsible for centrally receiving, classifying, storing, and permanently preserving this data. By building a cloud database, the system achieves orderly management of massive amounts of inspection data, allowing users to remotely access and query historical inspection data at any time. This enables full traceability and comprehensive analysis of the elevator wire rope's operational status, effectively improving the intelligence level and scientific basis of elevator safety management.

[0081] The online non-destructive testing method for elevator wire ropes in this embodiment utilizes scientifically arranged testing instruments, high-precision signal acquisition and transmission, professional data processing, and cloud data management to achieve real-time, accurate, and efficient non-destructive testing of elevator wire ropes, providing strong technical support for ensuring elevator operation safety.

[0082] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An elevator steel wire rope on-line detector, characterized by, The utility model relates to an elevator steel wire rope on-line detector, comprising: A main body part and a detection probe; the main body part comprises a main shell with a hollow structure, a main control panel is arranged inside the main shell, an alloy cover plate is arranged between the main control panel and the main shell; a clamping mechanism is arranged outside the main shell, the clamping mechanism is used for fixing the main shell on a traction machine steel beam; the detection probe comprises a probe shell with a single-face open structure, an amorphous wire sensor is arranged inside the probe shell, and a detection surface of the amorphous wire sensor faces an open surface of the probe shell; the number of amorphous wire sensors is two, and the amorphous wire sensors are arranged in parallel inside the probe shell along the length direction of the elevator steel wire rope; the main shell and the probe shell are connected through a metal goose neck pipe, the main control panel is electrically connected with the amorphous wire sensor through wires, is used for collecting the magnetic field intensity signal detected by the amorphous wire sensor, and the detection range of the amorphous wire sensor covers the position of the steel wire rope by adjusting the angle of the metal goose neck pipe; the alloy cover plate is made of permalloy, the main shell is made of aluminum alloy, and the metal goose neck pipe is made of nickel-titanium alloy; the amorphous wire sensor comprises an amorphous wire, a detection coil, a preamplifier, an analog switch, an integrator, a filter and a resistor, one end of the amorphous wire is connected with a pulse signal source, the other end is grounded, the detection coil is wound around the periphery of the amorphous wire and connected with the input end of the preamplifier, the output end of the preamplifier is connected with the first input end of the analog switch, the second input end of the analog switch is connected with the pulse signal source, the output end of the analog switch is connected with the input end of the integrator, the output end of the integrator is connected with the input end of the filter, the resistor is connected in parallel between the input end of the preamplifier and the input end of the filter, and the filter is used for outputting the magnetic field intensity analog signal detected by the detection coil.

2. The elevator steel wire rope on-line detector according to claim 1, characterized in that, A 4G data transmission module is further arranged inside the main shell, the 4G data transmission module is connected with the main control panel, and is used for uploading the data collected by the main control panel.

3. The elevator steel wire rope on-line detector according to claim 1, characterized in that, The clamping mechanism comprises an upper clamping plate, a lower clamping plate and a clamping plate shaft, the upper clamping plate and the lower clamping plate are rotatably connected on the clamping plate shaft, a first torsional spring is concentrically installed on the clamping plate shaft, and the two ends of the first torsional spring are respectively abutted with the upper clamping plate and the lower clamping plate, so that when the first torsional spring is compressed, the clamping ends of the upper clamping plate and the lower clamping plate are separated from each other; a clamping jaw is arranged at the clamping end of the lower clamping plate, the clamping jaw and the lower clamping plate are rotatably connected on a clamping jaw shaft, a second torsional spring is concentrically installed on the clamping jaw shaft, and the two ends of the second torsional spring are respectively abutted with the clamping jaw and the lower clamping plate, so that when the second torsional spring is compressed, the upper surface of the clamping jaw is parallel to the lower surface of the clamping end of the upper clamping plate.

4. An elevator non-destructive testing system comprising an elevator wire rope on-line tester, characterized by The utility model relates to an elevator steel wire rope on-line detector, comprising: A local computer running data receiving and processing software for communication with the elevator steel wire rope online detector, acquiring the elevator steel wire rope magnetic field strength signal collected by the elevator steel wire rope online detector, processing the elevator steel wire rope magnetic field strength signal, and identifying defects according to the processed magnetic field strength signal, wherein the identified defects include wear, rust, wire breakage, deformation, and internal stress change; A cloud server running data receiving and management software for communication with the data receiving and processing software, receiving the elevator steel wire rope magnetic field strength signal collected by the elevator steel wire rope online detector and the defect information identified by the data receiving and processing software, and updating the elevator equipment operation history data.

5. A non-destructive testing system for an elevator comprising an elevator wire rope on-line tester according to claim 4, characterized in that, The elevator non-destructive testing system further comprises: A local display large screen running display management software for communication with the data receiving and processing software, for graphical display of the processed magnetic field strength signal.

6. A non-destructive testing system for an elevator comprising an elevator wire rope on-line tester according to claim 4, characterized in that, The elevator non-destructive testing system further comprises a manned cloud 4G module installed in the elevator machine room to realize wireless communication connection between the cloud server and the local computer.

7. An online elevator steel wire rope non-destructive testing method, implemented based on the elevator non-destructive testing system of claim 4, characterized in that, The method comprises the following steps: At least four elevator steel wire rope online detectors are arranged circumferentially along the elevator steel wire rope, and the position of the elevator steel wire rope online detector is adjusted so that the vertical distance between the detection coil of the amorphous wire sensor of any elevator steel wire rope online detector and the elevator steel wire rope is 8-12 mm; The magnetic field strength signal on the steel wire rope is extracted in real time by the amorphous wire sensor, and the magnetic field strength signal is sent to the data receiving and processing software running on the local computer through the main control board of the elevator steel wire rope online detector; The data receiving and processing software processes the magnetic field strength signal and draws a magnetic field strength change curve, and identifies defects according to the shape change of the curve; The data receiving and processing software sends the processed magnetic field strength signal and the identified defect information to the data receiving and management software running on the cloud server for saving.

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