Steel wire rope nondestructive flaw detector

Abstract

The invention relates to the technical field of steel wire rope nondestructive testing, in particular to a steel wire rope nondestructive flaw detector. The device comprises an upper shell, a lower shell, a hinge assembly, a lock catch assembly, riding wheel assemblies, a magnetic circuit assembly, a sensor assembly, a bidirectional handle, an encoder assembly and an acquisition plate assembly, the upper shell and the lower shell are hinged through the hinge assembly, the lock catch assembly is fixed to the opening and closing position of the upper shell and the lower shell, and the four riding wheel assemblies are installed at the two ends of the upper shell and the two ends of the lower shell. The two magnetic circuit assemblies are fixed in inner cavities of the upper shell and the lower shell, the sensor assemblies are fixed in the magnetic circuit assemblies, the two-way handle is fixed above the upper shell, the two encoder assemblies are installed at the two ends of the two-way handle, and the collection plate assembly is fixed above the upper shell and located at the hollow position of the two-way handle. The acquisition board assembly is electrically connected with the encoder assembly and the sensor assembly. The device can adapt to various direct steel wire ropes, and the influence of steel wire rope shaking on the detection result is avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of nondestructive testing of steel wire ropes, and in particular to a nondestructive flaw detector for steel wire ropes. Background Art

[0002] In industries such as mining, coal mining, marine engineering, cranes, and bridge construction, wire ropes undoubtedly play a vital role in bearing the weight. To ensure safe operation, regular nondestructive testing of wire ropes is essential. Existing wire rope nondestructive flaw detectors suffer from issues such as excessive size, poor modularity, limited applicability, and susceptibility to wire rope vibration. Summary of the Invention

[0003] The purpose of the present invention is to solve the problems existing in the prior art and to propose a wire rope non-destructive flaw detector that can adapt to wire ropes of various diameters through modular design and avoid the influence of wire rope jitter on the detection results.

[0004] In order to achieve the above object, the technical solution provided by the present invention is:

[0005] A wire rope nondestructive flaw detector, comprising an upper shell, a lower shell, a hinge assembly, a lock assembly, and four roller assemblies. The upper shell and the lower shell are hingedly connected by the hinge assembly. The lock assembly is fixed at the opening and closing portion of the upper shell and the lower shell. The four roller assemblies are respectively installed at both ends of the upper shell and the lower shell. The instrument also includes two magnetic circuit assemblies, two sensor assemblies, a bidirectional handle, two encoder assemblies, and an acquisition board assembly.

[0006] A guide channel is provided between the upper shell and the lower shell for the steel wire rope to pass through, the two magnetic circuit assemblies are respectively fixed between the guide channel and the upper shell and between the guide channel and the lower shell, and the sensor assembly is fixed inside the magnetic circuit assembly;

[0007] The two-way handle is fixed above the upper shell, and the two encoder assemblies are respectively installed at the two ends of the two-way handle. The encoder assembly includes a wheel frame, a torsion spring, a tension spring, a coding wheel, an encoder and a rotating shaft. The rotating shaft passes through the wheel frame, the end of the two-way handle and the center hole of the torsion spring at the same time. The two legs of the torsion spring cooperate with the wheel frame and the two-way handle respectively. One end of the tension spring is fixed on the two-way handle, and the other end is fixed on the wheel frame. The torsion direction of the torsion spring is opposite to the extension and contraction direction of the tension spring. The coding wheel is installed at the lower end of the wheel frame through a support shaft and a bearing. The outer shell of the encoder is fixed on one side of the wheel frame, and the input shaft of the encoder is fixed to the coding wheel. The acquisition board assembly is fixed above the upper shell and is located in the hollow position of the two-way handle. The acquisition board assembly is electrically connected to the encoder assembly and the sensor assembly respectively.

[0008] Furthermore, a waist-shaped hole is provided on the two-way handle, and a limiting hole is provided on the wheel frame. One leg of the torsion spring passes through the waist-shaped hole, and the other leg passes through the limiting hole.

[0009] Furthermore, the magnetic circuit assembly includes two magnet fixings, several magnets and several armatures, the two magnet fixings are respectively fixed to the two ends of the armature, the cross-section of the magnet fixing is C-shaped, the several armatures are distributed on the outer arc surface of the magnet fixing, the several magnets are fixed in the magnet fixings and correspond one-to-one to the armatures, and a hollow cavity is formed between the two magnet fixings.

[0010] Furthermore, it also includes two filling pieces and two soft magnetic rings, the two filling pieces are respectively located in the hollow cavities of the two magnetic circuit components, the two filling pieces are respectively connected to the upper shell and the lower shell by screws, the soft magnetic ring is fixed to the inner side of the filling piece by screws, and the sensor assembly is fixed to the inner wall of the soft magnetic ring by screws.

[0011] Furthermore, the supporting wheel assembly includes a supporting wheel, a supporting wheel cross plate, two supporting wheel side plates, an angle adjustment plate, a supporting wheel shaft, a long hexagon socket screw, two anti-loosening nuts, two anti-loosening washers and two small copper sleeves. The angle adjustment plate, the supporting wheel cross plate and the supporting wheel shaft are sequentially installed between the two supporting wheel side plates. The supporting wheel side plates are sequentially provided with vertical limiting holes, central rectangular limiting holes and flat shaft limiting holes. The two ends of the angle adjustment plate are slidably installed in the vertical limiting holes. The two ends of the supporting wheel cross plate are fixedly installed in the central rectangular limiting holes of the two supporting wheel side plates. The supporting wheel shaft passes through the supporting wheel. The two ends of the supporting wheel shaft are fixed in the flat shaft limiting holes. The cam is provided with a plurality of screw threads, and the plurality of screw threads are connected to each other through the cam, and the plurality of screw threads are connected to each other through the cam, and the plurality of screw threads are connected to each other through the cam.

[0012] Furthermore, the acquisition board assembly includes an acquisition board lower shell, an acquisition board circuit board, an acquisition board upper shell and copper studs. The lower side of the acquisition board lower shell is provided with a mounting hole. The acquisition board assembly is fixed to the top of the upper shell by screws passing through the mounting hole. The copper studs are fixed to the acquisition board lower shell. The acquisition circuit board is fixed to the copper studs by screws. The acquisition board upper shell is fixed to the acquisition board lower shell by screws. A debugging port is provided on the acquisition board upper shell. A wire entry hole is provided on the side of the acquisition board lower shell. The output wire of the encoder enters through the wire entry hole and is connected to the acquisition circuit board. A downward wire entry port is provided on the bottom surface of the acquisition board lower shell. The output wires of the two sensor assemblies are connected to the acquisition circuit board through the downward wire entry port.

[0013] Furthermore, the sensor assembly includes a left shell, a pan head screw, a right shell, a short copper stud, a detection circuit board and a TMR chip. The TMR chip is integrated and welded on the detection circuit board. The detection circuit board is fixed to the right shell through a short copper stud. The left shell is fixed to the short copper stud through a pan head screw. A right shell mounting hole is provided on the right shell. The sensor assembly is fixed to the inner wall of the soft magnetic ring by screws passing through the right shell mounting hole. A circular protective cavity is formed between the two sensor assemblies.

[0014] Furthermore, it also includes four end connectors, a lower perforated plate, four bushings, two wire-outlet side cover plates and two side cover plates, the four end connectors are respectively fixed on the left and right sides of the upper shell and the lower shell, the lower perforated plate is fixed on the lower side of the lower shell, two of the four bushings are fixed to the upper shell, two are fixed to the lower shell, and are symmetrically distributed on both sides of the guide channel, the wire-outlet side cover plates and the side cover plates are located on the contact surface of the upper shell and the lower shell, the two wire-outlet side cover plates are close to the hinge assembly, and are respectively fixed to the upper shell and the lower shell, the two side cover plates are close to the locking assembly, and are respectively fixed to the upper shell and the lower shell, the right end face of the right shell body is in contact with the left end face of the bushing on the right side, and the left end face of the left shell body is in contact with the right end face of the bushing on the left side.

[0015] Furthermore, the lock assembly includes a lower lock plate, an upper lock plate and a spring lock, the spring lock is fixedly connected to the lower lock plate and the upper lock plate respectively by a first countersunk screw, the lower lock plate is provided with a lower lock plate mounting hole, the lock assembly is fixedly connected to the lower shell by a screw passing through the lower lock plate mounting hole, the upper lock plate is provided with an upper lock plate mounting hole, the lock assembly is fixedly connected to the upper shell by a screw passing through the upper lock plate mounting hole; the hinge assembly includes a hinge plate and a hinge, the upper and lower hinges of the hinge are fixedly connected to the upper and lower hinge plates respectively by a second countersunk screw, the hinge plate is provided with a hinge plate mounting hole, and the hinge assembly is fixedly connected to the upper shell and the lower shell by a screw passing through the hinge plate mounting hole.

[0016] Furthermore, the supporting wheel shaft includes two relatively arranged flat shaft planes and two relatively arranged flat shaft circular surfaces, the flat shaft planes form a clearance fit with the two flat shaft limiting holes, the flat shaft circular surfaces form a clearance fit with the supporting wheel, two small copper sleeves and two flat shaft limiting holes, both ends of the supporting wheel cross plate are provided with rectangular positioning steps, the rectangular positioning steps are inserted into the central rectangular limiting hole, and both ends of the angle adjustment plate are provided with rectangular limiting bosses, the rectangular limiting bosses are the same width as the vertical limiting holes, and are inserted into the vertical In the limiting hole, a side threaded hole is opened on the side of the rectangular positioning step, a side fixing threaded hole is opened on the side of the rectangular limiting boss, an axial threaded hole is opened at both ends of the supporting wheel shaft, and an angle adjustment plate mounting hole is opened at the fixing point of the angle adjustment plate and the upper shell or lower shell. By driving screws into the side threaded holes, the side fixing threaded holes or the axial threaded holes, the auxiliary wheel cross plate, the angle adjustment plate and the wheel axle are fixedly connected to the auxiliary wheel side plate, and by driving screws into the angle adjustment plate mounting holes, the supporting wheel assembly is fixed to the upper shell and the lower shell.

[0017] Compared with the prior art, the present invention has the following significant advantages: 1. The modular design of each part facilitates engineering expansion and application, especially in engineering production and online monitoring products, which can be reused to reduce development costs; 2. The design of four sets of roller assemblies can effectively limit the vibration range of the wire rope and ensure the accuracy of the sensor detection data; 3. The roller assembly can be adapted to the use of wire ropes of various diameters and can be adjusted as needed; 4. The design of two sets of encoders can greatly reduce the risk of the encoder wheel and the wire rope being separated, and improve the accuracy of the damage detection position; 5. The dual design of torsion spring and tension spring can avoid the situation where the encoder wheel is separated from the wire rope when the wire rope shakes greatly, thereby ensuring the accuracy of the test; 6. The inner diameter of the bushing, the soft magnetic ring and the sensor assembly can be replaced as needed, and the same set of magnetic circuits can be adapted to the detection of wire ropes of various specifications; 7. The magnetic circuit assembly and sensor designed according to the characteristics of the TMR chip give full play to the accuracy of TMR chip detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A perspective view of the lock assembly side of the present invention;

[0019] Figure 2 A perspective view of the hinge assembly side of the present invention;

[0020] Figure 3 A cross-sectional view of a nondestructive flaw detector for steel wire ropes according to the present invention;

[0021] Figure 4 This is a schematic diagram of the assembly of a non-destructive flaw detector for wire ropes according to the present invention;

[0022] Figure 5 Schematic diagram of a bidirectional handle and two encoder assemblies of the present invention;

[0023] Figure 6 is a cross-sectional view of the encoder assembly on the left side of the present invention;

[0024] Figure 7 is a schematic diagram of the acquisition board assembly of the present invention;

[0025] Figure 8 is a cross-sectional view of the collection plate assembly of the present invention;

[0026] Figure 9 is a schematic diagram of a lock assembly of the present invention;

[0027] Figure 10 is a schematic diagram of the supporting wheel assembly of the present invention;

[0028] Figure 11 is a cross-sectional view of the supporting wheel assembly of the present invention;

[0029] Figure 12 is a schematic diagram of a hinge assembly of the present invention;

[0030] Figure 13 is a schematic diagram of a magnetic circuit assembly of the present invention;

[0031] Figure 14 is a cross-sectional view of the magnetic circuit assembly of the present invention;

[0032] Figure 15 is a schematic diagram of a sensor assembly of the present invention;

[0033] Figure 16 is a cross-sectional view of a sensor assembly of the present invention;

[0034] Figure 17 Schematic diagram of the magnetization effect of the magnetic circuit assembly of the present invention on the wire rope;

[0035] Figure 18 This is a schematic diagram of the principle of magnetic flux leakage detection for wire rope damage according to the present invention.

[0036] Description of reference numerals:

[0037] 1. Encoder assembly, 2. Collection board assembly, 3. End connector, 4. Upper shell, 5. Lock assembly, 6. Lower shell, 7. Support roller assembly, 8. Hinge assembly, 9. Rubber shock absorber, 10. Lower perforated plate, 11. Bushing, 12. Magnetic circuit assembly, 13. Filler, 14. Soft magnetic ring, 15. Sensor assembly, 16. Outlet side cover, 17. Outlet hole, 18. Small screw, 19. Side cover, 20. Guide channel, 21. Wire rope, 101. End cover, 102. Left wheel frame, 103. Rotating shaft, 104. Spring Spring shaft, 105, two-way handle, 106, torsion spring, 107, right wheel frame, 108, coding wheel, 109, encoder, 110, small countersunk screw, 111, handle mounting hole, 112, tension spring, 113, long copper sleeve, 114, short copper sleeve, 115, set screw, 116, support shaft, 117, bearing, 118, retaining ring, 119, waist-shaped hole, 120, limit hole, 201, acquisition board lower shell, 202, acquisition circuit board, 203, wire entry hole, 204, acquisition board upper shell, 205, small pan head screw, 206, copper stud, 207, debugging port, 208, mounting hole, 209, downward cable inlet, 501, lower locking plate mounting hole, 502, lower locking plate, 503, upper locking plate, 504, upper locking plate mounting hole, 505, first countersunk screw, 506, spring lock, 701, supporting roller, 702, supporting roller cross plate, 703, supporting roller side plate, 704, angle adjustment plate, 705, long hexagon socket screw, 706, anti-loosening washer, 707, anti-loosening nut, 708, small copper sleeve, 709, supporting roller shaft, 710, screw Components, 801, hinge plate, 802, hinge plate mounting hole, 803, hinge, 804, second countersunk screw, 1201, magnet fixing part, 1202, armature, 1203, magnet baffle, 1204, third countersunk screw, 1205, magnet, 1206, hollow cavity, 1501, left shell, 1502, pan head screw, 1503, right shell, 1504, short copper stud, 1505, detection circuit board, 1506, right shell mounting hole, 1507, circular protective cavity, 1508, TMR chip. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0039] like Figures 1 to 4As shown, a wire rope nondestructive flaw detector of the present invention includes two encoder assemblies 1, a bidirectional handle 105, a collection plate assembly 2, four end connectors 3, an upper shell 4, a lock assembly 5, a lower shell 6, four roller assemblies 7, a hinge assembly 8, four rubber shock-absorbing pads 9, a lower perforated plate 10, four bushings 11, two magnetic circuit assemblies 12, two fillers 13, two soft magnetic rings 14, two sensor assemblies 15, two outlet side cover plates 16 and two side cover plates 19.

[0040] The upper shell 4 and the lower shell 6 are hinged by the hinge assembly 8 and can be opened and closed freely. The lock assembly 5 is fixed to the opening and closing of the upper shell 4 and the lower shell 6. The four end connectors 3 are fixed to the left and right sides of the upper shell 4 and the lower shell 6 respectively. The lower perforated plate 10 is fixed to the lower side of the lower shell 6. Two of the four bushings 11 are fixed to the upper shell 4 and two are fixed to the lower shell 6. They are symmetrically distributed on both sides of the guide channel 20. The outlet side cover plate 16 and the side cover plate 19 are located on the contact surface of the upper shell 4 and the lower shell 6. The two outlet side cover plates 16 are close to the hinge assembly 8 and are fixedly connected to the lower shell 6 and the upper shell 4 respectively by small screws 18. The two side cover plates 19 are close to the lock assembly 5 and are fixedly connected to the lower shell 6 and the upper shell 4 respectively by small screws 18. The four roller assemblies 7 are installed in groups of two at the left and right ends of the upper shell 4 and the lower shell 6 respectively, and are fixedly connected to the upper shell 4 and the lower shell 6 respectively by screws. A guide channel 20 is provided between the upper shell 4 and the lower shell 6 for passing a steel wire rope 21. Two magnetic circuit assemblies 12 are fixed in the internal cavity formed by the upper shell 4 and the lower shell 6 and the bushing 11, and are symmetrically distributed on both sides of the guide channel 20. The magnetic circuit assembly 12 contains a hollow cavity 1206. A filler 13 and a soft magnetic ring 14 are provided in the hollow cavity 1206. The filler 13 is connected to the upper shell 4 and the lower shell 6 respectively by screws. The soft magnetic ring 14 is fixed to the inside of the filler 13 by screws. The sensor assembly 15 is also fixed to the inner wall of the soft magnetic ring 14 by screws. Four rubber shock-absorbing pads 9 have their own studs and are fixedly connected to the lower shell 6 by threads, providing support for the entire wire rope flaw detector.

[0041] like Figure 5As shown, the two-way handle 105 is fixed to the upper part of the upper shell 4 by screws passing through the handle mounting holes 111. The two-way handle 105 has two handle mounting holes 111. Two encoder assemblies 1 are respectively mounted at both ends of the two-way handle 105. The encoder assembly 1 includes a wheel frame (for the convenience of subsequent force analysis, respectively recorded as the left wheel frame 102 and the right wheel frame 107), a torsion spring 106, a tension spring 112, an encoding wheel 108, an encoder 109, a rotating shaft 103 and two spring shafts 104. The rotating shaft 103 passes through the wheel frame, the end of the two-way handle 105 and the center hole of the torsion spring 106. The two-way handle 105 is provided with a waist-shaped hole 119, and the wheel frame is provided with a limiting hole 120. One leg of the torsion spring 106 passes through the waist-shaped hole 119, and the other leg passes through the limiting hole 120. One spring shaft 104 passes through the wheel frame and one end of the tension spring 112. The end of the spring shaft 104 is limited and connected by a retaining spring 118. This spring shaft 104 is used to connect and fix the left side of the tension spring 112. Another spring shaft 104 passes through the two-way handle 105 and the other end of the tension spring 112. The end is limited and connected by a retaining spring 118. In this way, the tension spring 112 is restricted between the two spring shafts 104. The torsion direction of the torsion spring 106 is opposite to the expansion and contraction direction of the tension spring 112. Figure 6 As shown, the encoder wheel 108 is mounted on the lower end of the wheel frame via a support shaft 116 and a bearing 117. The housing of the encoder 109 is screwed to one side of the wheel frame, and the encoder wheel 108 is fixed to the input shaft of the encoder 109 via a set screw 115, achieving an axially fixed connection between the encoder wheel 108 and the encoder 109. The encoder wheel 108 can drive the encoder 109 in synchronous rotation. A short copper sleeve 114 is installed between the encoder wheel 108 and the encoder 109, and a long copper sleeve 113 is installed between the bearing 117 and the encoder wheel 108. The bearing 117 is located inside the wheel frame. The support shaft 116 comprises a stepped shaft. The support shaft 116 on one side of the stepped shaft passes through the bearing 117. The end of the support shaft 116 on this side is axially fixed with a retaining spring 118. The support shaft 116 on the other side of the stepped shaft passes through the long copper sleeve 113 and then into the interior of the encoder wheel 108, providing support. One side of the stepped shaft mates with the end face of the bearing 117 to achieve axial fixed fixation. The end cover 101 is fixedly connected to the wheel frame by means of a small countersunk screw 110 , limits the bearing 117 , and is used to shield parts such as the bearing 117 and the support shaft 116 .

[0042] like Figures 7-8As shown, the acquisition board assembly 2 includes an acquisition board lower shell 201, an acquisition circuit board 202, an acquisition board upper shell 204, and copper studs 206. A wire entry hole 203 is provided on the side of the acquisition board lower shell 201. A mounting hole 208 and a downward wire entry port 209 are provided on the underside of the acquisition board lower shell 201. The acquisition board assembly 2 is secured to the upper portion of the upper shell 4 by screws passing through the mounting holes 208 and located in the hollow portion of the two-way handle 105. The copper studs 206 are secured to the acquisition board lower shell 201. The acquisition circuit board 202 is also secured to the copper studs 206. The acquisition board upper shell 204 is secured to the acquisition board lower shell 201 with small pan head screws 205. The output wires of the encoder 109 enter through the wire entry hole 203 and connect to the acquisition circuit board 202. The output wires of the sensor assembly 15 located in the upper shell 4 are connected to the acquisition circuit board 202 through the downward wire entry port 209. The outgoing wires from the sensor assembly 15, located within the lower housing 6, are routed downward through a semi-circular wire-passing cavity on the inner wall of the lower housing 6 near the hinge assembly 8. They then connect to the wire outlet hole 17 through a semi-circular wire-passing cavity on the inner wall of the upper housing 4 near the hinge assembly 8 and a downward wire inlet 209 to the acquisition circuit board 202. The upper housing 204 of the acquisition board is provided with a debug port 207, through which the outgoing wires from the debugging equipment enter the debugging process.

[0043] like Figure 9 As shown, the lock assembly 5 includes a lower lock plate 502, an upper lock plate 503, and a spring lock 506. The spring lock 506 is fixedly connected to the lower lock plate 502 and the upper lock plate 503 respectively via a first countersunk screw 505. The lower lock plate 502 is provided with a lower lock plate mounting hole 501, through which the lock assembly 5 is fixedly connected to the lower shell 6. The upper lock plate 503 is provided with an upper lock plate mounting hole 504, through which the lock assembly 5 is fixedly connected to the upper shell 4. The spring lock 506 is a four-position adjustable buckle, and the preload force of the spring lock 506 can be adjusted as needed to ensure the reliability of the upper and lower opening and closing structure of the wire rope flaw detector.

[0044] like Figures 10-11As shown, the supporting roller assembly 7 includes a supporting roller 701, a supporting roller cross plate 702, two supporting roller side plates 703, an angle adjustment plate 704, a supporting roller shaft 709, a long hexagon socket screw 705, a lock nut 707, a lock washer 706, two small copper sleeves 708 and a screw assembly 710. The angle adjustment plate 704, the supporting roller cross plate 702 and the supporting roller shaft 709 are sequentially installed between the two supporting roller side plates 703. The supporting roller side plates 703 are sequentially provided with vertical limiting holes, central rectangular limiting holes and flat shaft limiting holes. The two ends of the angle adjustment plate 704 are slidably installed in the vertical limiting holes. The two ends of the supporting roller cross plate 702 are fixedly installed in the central rectangular limiting holes of the two supporting roller side plates 703. The supporting roller shaft 709 passes through the supporting roller 701. The two ends are fixed in the flat shaft limiting holes, the angle adjustment plate 704 is provided with an angle positioning threaded hole, and the supporting roller cross plate 702 is provided with a center through hole. The long hexagon socket screw 705 passes through the angle positioning threaded hole, the upper anti-loosening nut 707, the upper anti-loosening washer 706, the center through hole, the lower anti-loosening washer 706 and the lower anti-loosening nut 707 in sequence. The upper anti-loosening nut 707 and the upper anti-loosening washer 706 are installed on the side of the supporting roller cross plate 702 facing the angle adjustment plate 704, and the lower anti-loosening washer 706 and the lower anti-loosening nut 707 are installed on the side of the supporting roller cross plate 702 facing the supporting roller 701. The two small copper sleeves 708 are respectively located between the supporting roller 701 and the two supporting roller side plates 703, and are mounted on the outside of the supporting roller shaft 709. The supporting roller shaft 709 includes two relatively arranged flat shaft planes and two relatively arranged flat shaft circular surfaces. The flat shaft planes form a clearance fit with the two flat shaft limiting holes. The flat shaft circular surfaces form a clearance fit with the supporting roller 701, two small copper sleeves 708 and the two flat shaft limiting holes. Rectangular positioning steps are provided at both ends of the supporting roller cross plate 702, and the rectangular positioning steps are inserted into the central rectangular limiting hole. Rectangular limiting bosses are provided at both ends of the angle adjustment plate 704. The rectangular limiting bosses are of the same width as the vertical limiting holes, and the rectangular limiting bosses are inserted into the vertical limiting holes. Side threaded holes are provided on the sides of the rectangular positioning steps, and side fixing threaded holes are provided on the sides of the rectangular limiting bosses. Axial threaded holes are provided at both ends of the supporting roller shaft 709, and angle adjustment plate mounting holes are provided at the fixing points of the angle adjustment plate 704 and the upper shell 4 or the lower shell 6. The screw assembly 710 includes eight screws, which are respectively driven into the side threaded holes, the side fixing threaded holes, the axial threaded holes and the angle adjustment plate mounting holes to fix the roller horizontal plate 702, the angle adjustment plate 704 and the roller shaft 709 to the roller side plates 703, and fix the roller assembly 7 to the upper shell 4 and the lower shell 6. The wheel surface of the roller 701 is an inward-concave arc surface, which can better surround the wire rope 21 while maintaining a gap with the wire rope 21 and adapt to wire ropes 21 of different diameters. Adjust the overall position of the roller 701, the roller horizontal plate 702 and the roller side plates 703, that is, the appropriate position of the roller 701 relative to the wire rope 21, and then tighten the upper anti-loosening nut 707 and the screw assembly 710 located on the outside of the two roller side plates 703.The supporting wheel 701 can limit the wire rope to a suitable inspection range.

[0045] like Figure 12 As shown, the hinge assembly 8 includes a hinge plate 801, a hinge plate mounting hole 802, a hinge 803, and a second countersunk screw 804. The upper and lower hinges of the hinge 803 are fixedly connected to the upper and lower hinge plates 801 via the second countersunk screw 804, respectively, forming a hinged connection between the upper and lower hinge plates 801. The hinge assembly 8 is fixedly connected to the upper and lower shells 4 and 6 via screws passing through the hinge plate mounting holes 802, creating a hinged connection between the upper and lower shells 4 and 6, allowing for free opening and closing.

[0046] like Figures 13-14 As shown, the magnetic circuit assembly 12 includes two magnet holders 1201, eight magnets 1205, and four armatures 1202. The two magnet holders 1201 are fixed to the ends of the armatures 1202, respectively. The magnet holders 1201 have a C-shaped cross-section. The four armatures 1202 are distributed on the outer curved surface of the magnet holders 1201, respectively located in the grooves of the left and right magnet holders 1201. They are locked to the magnet holders 1201 with third countersunk screws 1204. Four of the eight magnets 1205 are grouped together and located within the left and right magnet holders 1201, corresponding one-to-one with the armatures 1202. A hollow cavity 1206 is formed between the two magnet holders 1201. A magnet baffle 1203 is located within the hollow cavity 1206 and is fixed to the magnet holders 1201 via third countersunk screws 1204.

[0047] like Figures 15-16 As shown, the sensor assembly 15 includes a left housing 1501, a pan head screw 1502, a right housing 1503, a short copper stud 1504, a detection circuit board 1505, and a TMR chip 1508. The TMR chip 1508 is integrally welded on the detection circuit board 1505. The detection circuit board 1505 is fixed to the right housing 1503 via the short copper stud 1504. The left housing 1501 is fixed to the short copper stud 1504 via the pan head screw 1502. The right housing 1503 is provided with a right housing mounting hole 1506. The sensor assembly 15 is fixed to the inner wall of the soft magnetic ring 14 by screws passing through the right housing mounting hole 1506. The right end face of the right housing 1503 is in contact with the left end face of the right bushing 11, and the left end face of the left housing 1501 is in contact with the right end face of the left bushing 11. A circular protective cavity 1507 is formed between the two sensor assemblies 15 , and the circular protective cavity 1507 is coaxial with the guide channel 20 .

[0048] Take the horizontal linear motion of the wire rope 21 as an example to test it. The hinge assembly 8 connects the upper shell 4 and the lower shell 6 to form a hinge connection, which can be opened and closed freely. The lock assembly 5 connects the upper shell 4 and the lower shell 6 to form a hinge connection with a lock. Open the lock, the upper shell 4 and the lower shell 6 are in the open state, and the wire rope 21 is placed in the guide channel 20 formed by the bushing 11 and the sensor assembly 15 and the circular protective cavity 1507. Then close the upper shell 4 and the lower shell 6, the lock is in the closed state, and the wire rope 21 is located between the upper and lower roller assemblies 7. Adjust the position of the long hexagon socket screw 705, the anti-loosening nut 707 and the roller cross plate 702 so that the roller 701 is in the appropriate position, which can ensure that the wire rope 21 is in the center position of the bushing 11 and maintain an appropriate gap with the roller 701, ensuring that the wire rope 21 can move normally without wearing the bushing 11. At this point, the two encoder wheels 108 on the encoder assembly 1 rest against the upper surface of the wire rope 21, causing the torsion spring 106 to generate a compressive force under the pressure of the two-way handle 105 and the left wheel frame 102. Conversely, the reverse thrust generated by the torsion spring 106 acts on the left and right wheel frames, causing the encoder wheels 108 to apply a certain pressure to the wire rope 21. Similarly, the two encoder wheels 108 rest against the upper surface of the wire rope 21, causing the tension spring 112, under the action of the spring shaft 104 and the lower rotating shaft 103, to generate tension, thereby applying positive pressure to the encoder wheels 108. The combined action of the torsion spring 106 and the tension spring 112 ensures that the encoder wheels 108 maintain contact with the wire rope 21 despite the vibration of the wire rope 21. The combined action of the left and right encoders 109 and the encoder wheels 108 significantly reduces the risk of the encoder wheels 108 becoming detached from the wire rope 21 due to inertia, ensuring the accuracy of the test results.

[0049] When the wire rope 21 passes through the wire rope flaw detector and makes a horizontal linear motion in the left and right directions, the wire rope flaw detector is placed horizontally on a certain table, and the wire rope 21 is centered as much as possible relative to the center of the wire rope flaw detector. Then, by adjusting the roller assembly 7, the four rollers 701 are in the appropriate position, so that the wire rope 21 inside the wire rope flaw detector is centered relative to the wire rope flaw detector and a proper gap is retained. Figure 17 As shown, the magnetic circuit composed of the magnets 1205 and the armature 1202 on both sides of the magnetic circuit assembly 12 will uniformly saturate the steel wire rope 21 inside the steel wire rope flaw detector to form a stable magnetic field inside the steel wire rope. Figure 18As shown, the magnetic flux lines within the wire rope 21 change, generating air leakage magnetic flux at defects in the wire rope 21. The sensor assembly 15 captures these abnormal internal and external magnetic flux lines and collects signals via a detection circuit board 1505, which is soldered with a TMR chip 1508. The signals are then transmitted to a terminal for processing via a wired connection between a PC and the acquisition circuit board 202, thereby analyzing the damage signals of the wire rope 21.

[0050] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A wire rope nondestructive flaw detector, comprising an upper shell, a lower shell, a hinge assembly, a locking assembly, and four roller assemblies, wherein the upper shell and the lower shell are hingedly connected by the hinge assembly, the locking assembly is fixed at the opening and closing of the upper shell and the lower shell, and the four roller assemblies are respectively installed at both ends of the upper shell and the lower shell, characterized in that: It also includes two magnetic circuit assemblies, two sensor assemblies, a two-way handle, two encoder assemblies and an acquisition board assembly; A guide channel is provided between the upper shell and the lower shell for the steel wire rope to pass through, the two magnetic circuit assemblies are respectively fixed between the guide channel and the upper shell and between the guide channel and the lower shell, and the sensor assembly is fixed inside the magnetic circuit assembly; The two-way handle is fixed above the upper shell, and the two encoder assemblies are respectively installed at the two ends of the two-way handle. The encoder assembly includes a wheel frame, a torsion spring, a tension spring, a coding wheel, an encoder and a rotating shaft. The rotating shaft passes through the wheel frame, the end of the two-way handle and the center hole of the torsion spring at the same time. The two legs of the torsion spring cooperate with the wheel frame and the two-way handle respectively. One end of the tension spring is fixed on the two-way handle, and the other end is fixed on the wheel frame. The torsion direction of the torsion spring is opposite to the extension and contraction direction of the tension spring. The coding wheel is installed at the lower end of the wheel frame through a support shaft and a bearing. The outer shell of the encoder is fixed on one side of the wheel frame, and the input shaft of the encoder is fixed to the coding wheel. The acquisition board assembly is fixed above the upper shell and is located in the hollow position of the two-way handle. The acquisition board assembly is electrically connected to the encoder assembly and the sensor assembly respectively.

2. The wire rope nondestructive flaw detector according to claim 1, characterized in that: A waist-shaped hole is provided on the two-way handle, a limiting hole is provided on the wheel frame, one leg of the torsion spring passes through the waist-shaped hole, and the other leg passes through the limiting hole.

3. The wire rope nondestructive flaw detector according to claim 1, characterized in that: The magnetic circuit assembly includes two magnet fixing parts, several magnets and several armatures. The two magnet fixing parts are respectively fixed to the two ends of the armature. The cross-section of the magnet fixing part is C-shaped. The several armatures are distributed on the outer arc surface of the magnet fixing part. The several magnets are fixed in the magnet fixing part and correspond one-to-one to the armature. A hollow cavity is formed between the two magnet fixing parts.

4. The wire rope nondestructive flaw detector according to claim 1, characterized in that: It also includes two filling pieces and two soft magnetic rings, the two filling pieces are respectively located in the hollow cavities of the two magnetic circuit components, the two filling pieces are respectively connected to the upper shell and the lower shell by screws, the soft magnetic ring is fixed to the inner side of the filling piece by screws, and the sensor assembly is fixed to the inner wall of the soft magnetic ring by screws.

5. The wire rope nondestructive flaw detector according to claim 1, characterized in that: The supporting wheel assembly includes a supporting wheel, a supporting wheel cross plate, two supporting wheel side plates, an angle adjustment plate, a supporting wheel shaft, a long hexagon socket screw, two anti-loosening nuts, two anti-loosening washers and two small copper sleeves. The angle adjustment plate, supporting wheel cross plate and supporting wheel shaft are sequentially installed between the two supporting wheel side plates, and the supporting wheel side plates are sequentially opened with vertical limiting holes, central rectangular limiting holes and flat shaft limiting holes. The two ends of the angle adjustment plate are slidably installed in the vertical limiting holes, and the two ends of the supporting wheel cross plate are fixedly installed in the central rectangular limiting holes of the two supporting wheel side plates. The supporting wheel shaft passes through the supporting wheel, and the two ends of the supporting wheel shaft are fixed in the flat shaft limiting holes. The angle adjustment plate is provided with an angle positioning threaded hole, and the supporting roller cross plate is provided with a center through hole. The long hexagon socket screw passes through the angle positioning threaded hole, the upper anti-loosening nut, the upper anti-loosening washer, the center through hole, the lower anti-loosening washer and the lower anti-loosening nut in sequence. The upper anti-loosening nut and the upper anti-loosening washer are installed on the side of the supporting roller cross plate facing the angle adjustment plate, and the lower anti-loosening washer and the lower anti-loosening nut are installed on the side of the supporting roller cross plate facing the supporting roller. The two small copper sleeves are respectively located between the supporting roller and the two supporting roller side plates, and are mounted on the outside of the supporting roller shaft. The wheel surface of the supporting roller is an inward-concave arc surface.

6. The wire rope nondestructive flaw detector according to claim 1, characterized in that: The acquisition board assembly includes an acquisition board lower shell, an acquisition board circuit board, an acquisition board upper shell and copper studs. The lower side of the acquisition board lower shell is provided with a mounting hole. The acquisition board assembly is fixed to the top of the upper shell by screws passing through the mounting hole. The copper studs are fixed to the acquisition board lower shell. The acquisition circuit board is fixed to the copper studs by screws. The acquisition board upper shell is fixed to the acquisition board lower shell by screws. A debugging port is provided on the acquisition board upper shell. A wire entry hole is provided on the side of the acquisition board lower shell. The output wire of the encoder enters through the wire entry hole and is connected to the acquisition circuit board. A downward wire entry port is provided on the bottom surface of the acquisition board lower shell. The output wires of the two sensor assemblies are connected to the acquisition circuit board through the downward wire entry port.

7. The wire rope nondestructive flaw detector according to claim 1, characterized in that: The sensor assembly includes a left shell, a pan head screw, a right shell, a short copper stud, a detection circuit board and a TMR chip. The TMR chip is integrated and welded on the detection circuit board. The detection circuit board is fixed to the right shell through a short copper stud. The left shell is fixed to the short copper stud through a pan head screw. A right shell mounting hole is provided on the right shell. The sensor assembly is fixed to the inner wall of the soft magnetic ring by screws passing through the right shell mounting hole. A circular protective cavity is formed between the two sensor assemblies.

8. The wire rope nondestructive flaw detector according to claim 7, characterized in that: It also includes four end connectors, a lower perforated plate, four bushings, two wire-outlet side cover plates and two side cover plates, the four end connectors are respectively fixed on the left and right sides of the upper shell and the lower shell, the lower perforated plate is fixed on the lower side of the lower shell, two of the four bushings are fixed to the upper shell, two are fixed to the lower shell, and are symmetrically distributed on both sides of the guide channel, the wire-outlet side cover plates and the side cover plates are located on the contact surface of the upper shell and the lower shell, the two wire-outlet side cover plates are close to the hinge assembly, and are respectively fixed to the upper shell and the lower shell, the two side cover plates are close to the locking assembly, and are respectively fixed to the upper shell and the lower shell, the right end face of the right shell body is fitted with the left end face of the bushing on the right side, and the left end face of the left shell body is fitted with the right end face of the bushing on the left side.

9. The wire rope nondestructive flaw detector according to claim 1, characterized in that: The lock catch assembly includes a lower lock catch plate, an upper lock catch plate and a spring lock catch, the spring lock catch is fixedly connected to the lower lock catch plate and the upper lock catch plate respectively by a first countersunk screw, the lower lock catch plate is provided with a lower lock catch plate mounting hole, the lock catch assembly is fixedly connected to the lower shell by a screw passing through the lower lock catch plate mounting hole, the upper lock catch plate is provided with an upper lock catch plate mounting hole, the lock catch assembly is fixedly connected to the upper shell by a screw passing through the upper lock catch plate mounting hole; the hinge assembly includes a hinge plate and a hinge, the upper and lower hinges of the hinge are fixedly connected to the upper and lower hinge plates respectively by a second countersunk screw, the hinge plate is provided with a hinge plate mounting hole, and the hinge assembly is fixedly connected to the upper shell and the lower shell by a screw passing through the hinge plate mounting hole.

10. The wire rope nondestructive flaw detector according to claim 5, characterized in that: The supporting wheel shaft includes two relatively arranged flat shaft planes and two relatively arranged flat shaft circular surfaces. The flat shaft planes form a clearance fit with the two flat shaft limiting holes. The flat shaft circular surfaces form a clearance fit with the supporting wheel, two small copper sleeves and two flat shaft limiting holes. Both ends of the supporting wheel cross plate are provided with rectangular positioning steps, and the rectangular positioning steps are inserted into the central rectangular limiting hole. Both ends of the angle adjustment plate are provided with rectangular limiting bosses, and the rectangular limiting bosses are the same width as the vertical limiting holes and are inserted into the vertical limiting holes. A side threaded hole is provided on the side of the rectangular positioning step, a side fixing threaded hole is provided on the side of the rectangular limiting boss, an axial threaded hole is provided at both ends of the supporting wheel shaft, and an angle adjustment plate mounting hole is provided at the fixing position of the angle adjustment plate to the upper shell or the lower shell. By driving screws into the side threaded holes, the side fixing threaded holes or the axial threaded holes, the auxiliary wheel cross plate, the angle adjustment plate and the wheel axle are fixedly connected to the auxiliary wheel side plate. By driving screws into the angle adjustment plate mounting holes, the supporting wheel assembly is fixed to the upper shell and the lower shell.

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