Elevator steel cable fault detection system and detection method

Abstract

The invention provides a fault detection system and a fault detection method for a steel cable of an elevator, and aims to solve the technical problems of complex structure, poor anti-interference performance and the like of existing detection equipment for the steel cable of the elevator. The fault detection system comprises a bending guide rail unit for forcing a steel cable to form an S-shaped bending path; the positioning coding unit is arranged above the S-shaped bending guide rail unit and is used for recording the moving distance of the steel cable in real time; and the pressure detection unit is arranged on the bending guide rail unit. The detection method comprises the following steps: S10, enabling a steel cable to bypass a first roller group and a second roller group to move along an S-shaped bending path; s20, recording a moving distance value of the steel cable through a positioning coding unit, and recording a pressure value through a pressure detection unit; s30, judging whether the steel cable is damaged or not according to the pressure value and the distance value; and S40, marking the damaged position of the steel cable through the positioning coding unit. The detection system and the detection method have the advantages of being simple in structure, high in anti-interference performance and free of dependence on electronic intelligent analysis.

Description

Technical Field

[0001] This invention relates to the field of hoist testing technology, and more specifically to a fault detection system and method for hoist steel cables. Background Technology

[0002] As a core component carrying personnel and materials, the safety status of mine hoist steel cables is directly related to the safety of mine production.

[0003] Traditional steel cable fault diagnosis mainly relies on regular manual visual inspection and periodic forced replacement strategies, which have two major drawbacks: First, hidden damage such as broken wires and wear inside the steel wire rope is difficult to detect through surface observation, creating significant safety hazards; Second, although online monitoring systems based on electronic sensors (such as electromagnetic flaw detection and acoustic emission detection) can achieve automated diagnosis, their reliability is significantly reduced in the high dust, high humidity and strong electromagnetic interference environment of mines, and they require complex signal processing algorithms and high maintenance costs.

[0004] Furthermore, existing mechanical detection devices mostly rely on the tensile deformation or vibration characteristics of steel cables, resulting in a sluggish response to local stiffness degradation and difficulty in accurately locating early damage points. The industry urgently needs a fault diagnosis method that is simple in structure, highly resistant to interference, and does not rely on electronic intelligent analysis, to achieve highly robust, low-cost real-time monitoring under harsh operating conditions, filling the technological gap in purely mechanical reliable detection. Summary of the Invention

[0005] To address the technical problems of existing hoist steel cable testing equipment, such as complex structure and poor anti-interference ability, this invention provides a hoist steel cable fault detection system and method, which has the advantages of simple structure, strong anti-interference ability and no need to rely on electronic intelligent analysis.

[0006] The technical solution of this invention is: A fault detection system for hoist steel cables, comprising: The bending guide rail unit forces the steel cable to form an S-shaped bending path; A positioning encoding unit is located above the S-shaped bending guide rail unit and connected to the steel cable, used to record the moving distance of the steel cable in real time; A pressure detection unit is installed on the bending guide rail unit to measure the lateral pressure generated on the steel cable when it passes through the bending guide rail unit.

[0007] Optionally, the bending guide rail unit includes: The first roller assembly includes a fixed roller and an adjustable roller; The second roller assembly is connected to the pressure detection unit.

[0008] Optionally, the positioning encoding unit includes: The coding rollers are in direct contact with the steel cable; A mechanical counter, connected to the encoding roller, is used to record the path distance of the encoding roller as it rolls on the steel cable.

[0009] Optionally, the pressure detection unit includes: The telescopic component is connected to the bending guide rail unit; A measuring element, connected to the telescopic component, is used to measure the pressure value borne by the telescopic component.

[0010] Optionally, it also includes: The cleaning unit, located at the entrance of the steel cable, is used to clean the surface of the steel cable of any adhering substances.

[0011] Optionally, the cleaning unit includes: Multiple brushes are arranged in a ring and surround the circumference of the steel cable; Multiple clamping elements are provided for each brush body to clamp the brush body onto the steel cable.

[0012] A method for fault detection of hoist steel cable includes the following steps: S10. Make the steel cable pass around the first roller group and the second roller group, and move it at a constant speed along the S-shaped curved path; S20. The distance the steel cable moves is recorded by the positioning coding unit, and the pressure value generated by the steel cable on the second roller group is recorded by the pressure detection unit. S30. Determine whether the steel cable is damaged based on the pressure and distance values; S40. Mark the location of the damaged steel cable using the positioning coding unit.

[0013] Optionally, in step S30, when the pressure value detected by the pressure detection unit shows a significant decrease within the long distance range recorded by the positioning encoding unit, it is determined that the steel cable is damaged at that location.

[0014] Optionally, in step S30, when the pressure value decreases by more than 15% within a range of continuous movement distance greater than 0.1 meters, it is determined that the steel cable is damaged at that location.

[0015] Optionally, in step S40, the location of the damaged steel cable is marked by a sprayer in the positioning coding unit.

[0016] Compared with the prior art, the beneficial effects of the present invention are: The steel cable is forced into an S-shaped bending path by a bending guide unit, and then the movement distance of the steel cable is measured in real time by a positioning coding unit, which is used to mark the damage points of the steel cable. The damage points of the steel cable are detected by a pressure detection unit.

[0017] This technical solution achieves accurate detection of steel cable damage points through a simple mechanical structure. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this application 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 only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the detection system structure of the present invention; Figure 2 This is a flowchart illustrating the detection method steps. Figure 3 This is a structural diagram of the cleaning unit; Figure 4 This is a schematic diagram of the positioning coding unit. Detailed Implementation

[0020] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0021] The following disclosure provides many different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, examples of various specific processes and materials are provided in this invention, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0022] The embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0023] Example 1

[0024] See Figure 1This embodiment discloses a fault detection system and method for a hoist cable, including a bending guide rail unit 10, a positioning coding unit 30, and a pressure detection unit 40. The bending guide rail unit 10, positioning coding unit 30, and pressure detection unit 40 are all disposed on the path of the hoist cable 20. The bending guide rail unit 10 can forcibly form an S-shaped bending path. The positioning coding unit 30 is disposed in front of the bending guide rail unit 10 and connected to the cable 20. The positioning coding unit 30 is used to record the moving distance of the cable 20 in real time, so as to record the damage location in real time when a damage point is detected on the cable 20. The pressure detection unit 40 is disposed on the bending guide rail unit 10 and is used to measure the lateral pressure generated on the cable 20 when it passes through the bending guide rail unit 10. The pressure change of the cable 20 is used to determine whether there is damage to the cable 20.

[0025] In this embodiment, the characteristic that localized damage (such as broken wires or wear) to the steel cable 20 leads to a decrease in local bending stiffness is utilized. When the steel cable 20 passes through a specific bending path, the damaged area will produce an abnormal deformation response. The fault point is identified by measuring the abrupt change in the lateral rebound force when the steel cable 20 bends. This technical solution can achieve accurate detection of damage points in the steel cable 20 through a simple mechanical structure.

[0026] In one specific embodiment: See Figure 1 The bending guide rail unit 10 includes a first roller group 11 and a second roller group 12. The first roller group 11 includes a fixed roller 111 and an adjustable roller 112. The fixed roller 111 is fixed in position, and the adjustable roller 112 is mounted on a spiral lifting platform 113. The distance between the adjustable roller 112 and the fixed roller 111 is controlled by the spiral lifting platform 113.

[0027] The second roller assembly 12 includes a pressure-measuring roller 121 and a guide roller 122. The pressure-measuring roller 121 is mounted on the pressure detection unit 40, which mainly detects the pressure of the steel cable 20 on the pressure-measuring roller 121. Both the pressure-measuring roller 121 and the guide roller 122 are mounted on a fixed bracket, and their positions are fixed.

[0028] Specifically, the fixed roller 111, adjustable roller 112, pressure measuring roller 121, and guide roller 122 are arranged sequentially from top to bottom, and the axes of all rollers are set in the horizontal direction. The steel cable 20 is introduced from above the fixed roller 111 in an inclined direction, passes around on the same side of the adjustable roller 112, and then passes around on the other side of the pressure measuring roller 121 and guide roller 122, thus forming an S-shaped structure.

[0029] In this embodiment, a fixed roller 111 is provided to fix the position of the steel cable 20 entering the system, an adjustable roller 112 is provided to adjust the sensitivity of the test, and an exit roller 122 is provided to fix the position of the steel cable 20 exiting the system.

[0030] The first roller group 11 is used to control the initial bending strength of the steel cable 20 and adjust the sensitivity through the adjustable roller 112. When the adjustable roller 112 is close to the fixed roller 111, the bending arc of the section of steel cable 20 between the fixed roller 111 and the adjustable roller 112 becomes smaller and the radius of curvature increases, thus reducing the test sensitivity. Conversely, the sensitivity increases.

[0031] The second roller assembly 12 is a precision testing component that requires absolute stability, so it is mounted on a fixed support.

[0032] Preferably, the spiral lifting platform 113 mainly includes a platform and a drive structure such as a screw. Adjustable rollers 112 are mounted on the platform, and the screw uses a universal threaded connection structure to drive the platform to move up and down. Additionally, a limiting structure can be provided on the spiral lifting platform 113.

[0033] In another specific embodiment: See Figure 4 The positioning encoding unit 30 includes an encoding roller 31 and a mechanical counter 32. The encoding roller 31 is in direct contact with the steel cable 20, so that the steel cable 20 can directly drive the encoding roller 31 to rotate during movement. The mechanical counter 32 is connected to the encoding roller 31 and achieves accurate counting through multiple meshing gears inside the mechanical counter 32.

[0034] For example, a gear for driving the mechanical counter 32 can be coaxially set on the encoding roller 31, and then multiple digital wheels inside the mechanical counter 32 can be driven through the multi-stage gears inside the mechanical counter 32 to achieve the purpose of counting.

[0035] In another specific embodiment: The pressure detection unit 40 includes a telescopic component 41 and a measuring component 42. One end of the telescopic component 41 is rotatably connected to the aforementioned pressure measuring roller 121, and the measuring component 42 is connected to the telescopic component 41.

[0036] Specifically, the telescopic component 41 is a hydraulic piston actuator, and the pressure measuring roller 121 is rotatably mounted on the end of the piston. A return spring is also fitted onto the piston, and the piston extension is primarily driven by the return spring.

[0037] The measuring element 42 includes an oil pipeline connecting the telescopic element 41, a Boulden tube, and a mechanical instrument. When the pressure value of the steel cable 20 on the pressure measuring roller 121 increases or decreases, the oil pressure changes, and the Boulden tube deforms accordingly. The deformation of the Boulden tube drives the deflection of the mechanical instrument, thereby displaying the pressure value.

[0038] In another specific embodiment: like Figure 3 As shown, the fault detection system also includes a cleaning unit 50, which is located in front of the bending guide rail unit 10 and is mainly used to clean the attachments on the steel cable 20 to improve the accuracy of the measurement.

[0039] Specifically, the cleaning unit 50 includes multiple brushes 51 and clamping members 52, wherein all brushes 51 are in contact with the surface of the steel cable 20, and all brushes 51 are arranged around the circumference of the steel cable 20. A clamping member 52 is provided behind each brush 51, which can press the brush 51 firmly against the surface of the steel cable 20.

[0040] Preferably, the clamping element 52 is a spring.

[0041] Example 2

[0042] See Figure 2 This embodiment discloses a fault detection method for a hoist cable 20, including the following steps: S10, make the steel cable 20 pass around the first roller group 11 and the second roller group 12, and move at a constant speed along the S-shaped curved path.

[0043] The steel cable 20 is pulled through the bending guide rail unit 10 at a constant speed of 0.2-1.0 m / s. A speed below 0.2 m / s results in too few signal sampling points, potentially leading to missed short-circuit damage. Due to the response delay of the mechanical encoder, the speed should not exceed 1.0 m / s; otherwise, the positioning error will increase.

[0044] S20. The positioning coding unit 30 records the distance traveled by the steel cable 20 and outputs the distance value in real time, requiring the accuracy of the distance value to be within 0.01m. The pressure detection unit 40 records the pressure value generated by the steel cable 20 on the second roller group 12.

[0045] S30. Determine whether the steel cable 20 is damaged based on the pressure and distance values. When the pressure value detected by the pressure detection unit 40 shows a significant decrease within the long distance range recorded by the positioning coding unit 30, it is determined that the steel cable 20 is damaged at that location. Generally, when the pressure value decreases by more than 15% within a continuous movement distance greater than 0.1 meters, it is determined that the steel cable 20 is damaged at that location.

[0046] S40. The damaged location of the steel cable 20 is marked by the positioning coding unit 30, and the damaged location of the steel cable 20 is applied by the sprayer in the positioning coding unit 30.

[0047] The detection method in this technical solution is mainly based on the principles of materials mechanics and structural dynamics. It diagnoses faults by detecting abnormal mechanical responses caused by a decrease in the local bending stiffness of the steel cable 20.

[0048] Specifically, the bending resistance of the healthy steel cable 20 satisfies the bending theory of beams.

[0049] Where E is the elastic modulus (material property) and I is the moment of inertia of the cross section (geometric property). For a steel cable 20 with diameter d (approximately a solid circular shaft).

[0050] Based on the bending resistance, it can be concluded that the larger the EI, the larger the required bending force F.

[0051] Stiffness collapse of damaged steel cable 20: The breakage of steel wires leads to a reduction in the effective load-bearing area. For example, if three wires break, I decreases by about 35%.

[0052] Severe wear leads to a reduction in diameter; for example, a 10% reduction in diameter results in a decrease in I of approximately 34%.

[0053] When an indentation occurs, the cross-section is distorted and the distribution of the moment of inertia is unbalanced. For example, when the indentation depth is 2 mm, I decreases by about 22%.

[0054] In summary, it can be concluded that the damaged area is more prone to deformation under the same bending path, thus the forced bending force required to be applied by the pressure measuring roller 121 will be significantly reduced.

[0055] In this technical solution, the purpose of designing the S-shaped bending path is to enhance the contrast. When the healthy section of the steel cable 20 passes through the first roller group 11 and the second roller group 12, both bends require high bending forces. However, because the damaged section is pre-bent by the first roller group 11 and its stiffness is reduced, the sudden drop in pressure is more significant when it passes through the second roller group 12.

[0056] In addition, designing a double-bending path can suppress false signals. Single bending points are easily affected by tension fluctuations, while S-shaped double bends can filter out unidirectional interference.

[0057] In step S30, the condition for determining the damage point is set to a continuous distance greater than 0.1 meters. The reason for this is that when the damaged area passes through the S-bend, the pressure drop needs to last for a sufficient length to eliminate instantaneous interference.

[0058] In this embodiment, the entire system is implemented using a simple mechanical structure without the need for an electronic system. The fault is determined directly by the pointer offset amplitude of the mechanical instrument and the mechanical counting of the positioning coding unit 30, and it has strong anti-interference capabilities.

[0059] The embodiments described above are merely illustrative of specific implementations of the present invention, and while the descriptions are detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.

Claims

1. A fault detection system for hoist steel cables, characterized in that, include: The bending guide rail unit forces the steel cable to form an S-shaped bending path; A positioning encoding unit is located above the S-shaped bending guide rail unit and connected to the steel cable, used to record the moving distance of the steel cable in real time; A pressure detection unit is installed on the bending guide rail unit to measure the lateral pressure generated on the steel cable when it passes through the bending guide rail unit.

2. The fault detection system according to claim 1, characterized in that, The bending guide rail unit includes: The first roller assembly includes a fixed roller and an adjustable roller; The second roller assembly is connected to the pressure detection unit.

3. The fault detection system according to claim 1, characterized in that, The positioning encoding unit includes: The coding rollers are in direct contact with the steel cable; A mechanical counter, connected to the encoding roller, is used to record the path distance of the encoding roller as it rolls on the steel cable.

4. The fault detection system according to claim 1, characterized in that, The pressure detection unit includes: The telescopic component is connected to the bending guide rail unit; A measuring element, connected to the telescopic component, is used to measure the pressure value borne by the telescopic component.

5. The fault detection system according to claim 1, characterized in that, Also includes: The cleaning unit, located at the entrance of the steel cable, is used to clean the surface of the steel cable of any adhering substances.

6. The fault detection system according to claim 5, characterized in that, The cleaning unit includes: Multiple brushes are arranged in a ring and surround the circumference of the steel cable; Multiple clamping elements are provided for each brush body to clamp the brush body onto the steel cable.

7. A method for fault detection of hoist steel cable, characterized in that, Includes the following steps: S10. Make the steel cable pass around the first roller group and the second roller group, and move it at a constant speed along the S-shaped curved path; S20. The distance the steel cable moves is recorded by the positioning coding unit, and the pressure value generated by the steel cable on the second roller group is recorded by the pressure detection unit. S30. Determine whether the steel cable is damaged based on the pressure and distance values; S40. Mark the location of the damaged steel cable using the positioning coding unit.

8. The detection method according to claim 7, characterized in that, In step S30, when the pressure value detected by the pressure detection unit shows a significant decrease within the long distance range recorded by the positioning encoding unit, it is determined that the steel cable is damaged at that location.

9. The detection method according to claim 8, characterized in that, In step S30, when the pressure value decreases by more than 15% within a range of continuous movement distance greater than 0.1 meters, it is determined that the steel cable is damaged at that location.

10. The detection method according to claim 7, characterized in that, In step S40, the location of the damaged steel cable is marked by a sprayer in the positioning coding unit.

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