Low-cost armature-free embedded elevator steel wire rope damage intelligent detection device

Abstract

The invention discloses an elevator steel wire rope magnetic flux leakage detection device without an armature structure, belongs to the technical field of elevator safety monitoring, and is characterized in that a traditional armature is replaced by the structure of an elevator. The magnetic flux leakage signal acquisition module is composed of a radially surrounding patch Hall element and a polyimide flexible carrier, a gap between the element and the surface of a steel wire rope is not more than 0.5 mm, and non-blind area magnetic flux leakage acquisition is realized; the magnetic flux leakage signal acquisition module is constructed based on a DAQ data rapid acquisition assistant, integrates a multi-channel amplifier and a synchronous analog-to-digital converter, and supports power-down seamless switching. The signal processing and damage identification module adopts db4 wavelet basis five-layer noise reduction, and is matched with a lightweight adaptive threshold algorithm and a convolutional neural network model trained by MATLAB, and the detection rate of broken wire damage with the diameter not smaller than 0.2 mm is not lower than 98%. The weight of the device does not exceed 2 kilograms, the cost is one tenth of that of a traditional scheme, tool-free embedded installation is achieved, and the device is suitable for various elevators.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of elevator safety monitoring, and in particular to a low-cost, lightweight, online steel wire rope damage detection device and method that cancels the traditional armature and directly uses the existing metal base of an elevator as a magnetic flux loop. BACKGROUND

[0002] The statements herein merely provide background technology related to the present application and do not necessarily constitute prior art.

[0003] At present, the known elevator steel wire rope damage detection devices mostly adopt an armature type magnetization structure, the core of which is composed of a C-shaped electromagnet, a high-precision Hall sensor array and a signal processing module. Representative technologies include the German Foerster armature type system and the Japanese Sumitomo pulse eddy current detector, which are mainly applied to special equipment inspection institutions, high-end maintenance and industrial special scenarios.

[0004] Such technologies magnetize the steel wire rope to a near-saturation state through a strong magnetic field. When the steel wire rope has broken wires, wear or corrosion, the magnetic permeability of the damaged part changes, causing a magnetic leakage field, which is captured by the Hall sensor. However, such detection devices have the following obvious shortcomings: High cost: the cost of a single magnetization component exceeds 30,000 yuan, and the overall equipment sells for 3-15,000 yuan, making it difficult for small and medium-sized properties and old communities to popularize; bulky: the weight of the electromagnet generally exceeds 15 kg, and the overall volume is large, requiring professional personnel to spend several hours on site installation; limited functionality: the device requires 380V industrial power supply support, with a peak instantaneous power of 1500W, and can only achieve offline sampling inspection, which cannot meet the real-time monitoring requirements; complex deployment: requires additional structures such as guide rail supports, and the installation process is complicated, making it difficult to be widely used in existing elevator systems; existing technology deficiencies: high equipment cost (3-15,000 yuan per unit), complex operation and maintenance; relies on offline detection, cannot monitor in real time; bulky (magnetization module exceeds 15 kg), requires professional installation; more than 75% of the core sensors are imported, and the environment with high humidity is easily disturbed, and the data cannot be synchronized in real time.

[0005] Problems to be solved: reduce the cost of the detection device, achieve real-time online monitoring, reduce the volume for easy installation, reduce dependence on imported sensors, and improve environmental adaptability. SUMMARY

[0006] In order to solve the above problems, the application provides a low-cost embedded elevator steel wire rope damage intelligent detection device without armature.

[0007] In order to achieve the above purpose, the application is realized by the following technical scheme: In the first aspect, the application provides an elevator steel wire rope magnetic flux leakage detection device based on a structure without armature, characterized in that it comprises: The excitation module replaces the traditional magnetic flux leakage detection armature structure with an elevator iron structure; the upper permanent magnet and the lower permanent magnet are fixed on the two sides of the elevator steel wire rope in an N-S pole opposite manner, forming a magnetization channel for the steel wire rope to pass through; the steel wire rope is magnetized to a saturation magnetic flux density, and when the steel wire rope has broken wires, wear or corrosion, the local magnetic resistance suddenly changes to produce a magnetic flux leakage field; The magnetic flux leakage signal acquisition module includes a no-armature patch type Hall sensor array and a flexible circuit carrier, wherein the no-armature patch type Hall sensor array is composed of multiple groups of patch Hall elements, each group of patch Hall elements is arranged in a linear array along the axial direction of the steel wire rope, and the multiple groups of patch Hall elements are arranged around the steel wire rope in the radial direction to surround the outer periphery of the steel wire rope as a whole; the flexible circuit carrier adopts a flexible polyimide substrate to realize the centralized extraction of the output signals of the patch Hall elements; The magnetic flux leakage signal acquisition module realizes the data acquisition task based on the DAQ data rapid acquisition assistant method, which only needs to configure the data type, sampling device, sampling type, sampling parameters and other information in the DAQ data acquisition assistant, without programming, and can generate a data acquisition subprogram, and the running program can output the sampling data, which has the characteristics of convenience, speed, simple programming, etc. The magnetic flux leakage signal processing module uses wavelet threshold denoising to decompose the original data into wavelet decomposition coefficients at different scales, and quantizes the wavelet coefficients at different scales of the signal according to the threshold function to achieve the purpose of suppressing and removing damage noise. The damage identification module transplants the identification model into the LabVIEW program block diagram by calling the MATLAB script VI, and realizes damage identification and outputs the damage identification result based on the LabVIEW platform calling the broken wire damage identification model trained in MATLAB. The result generation module creates a report, adds a report file, and disposes of the report in LabVIEW, that is, writes and modifies the detection report. A magnetic flux leakage signal transmitting module is installed on the side of the elevator upper support, which is used for wirelessly receiving structured data and forwarding to the result generating module.

[0008] Further, the permanent magnet excitation unit uses the elevator base as part of the magnetic flux return path, replacing the traditional magnetic flux leakage detection armature structure with the elevator iron structure, thereby eliminating the traditional C-shaped or U-shaped armature.

[0009] Further, the armature-free patch type Hall sensor array includes at least two groups of linearly arranged patch Hall elements, which are symmetrically arranged on the two sides of the steel wire rope in the radial direction, and the gap between the patch Hall elements and the surface of the steel wire rope is ≤0.5 mm.

[0010] Further, the patch Hall elements are welded to the flexible circuit board, and the flexible circuit board is fixed to the outer periphery of the steel wire rope by a non-magnetic clamp, realizing omnidirectional detection without blind area.

[0011] Further, the embedded main control unit runs a lightweight adaptive threshold algorithm, and the computational complexity is reduced by ≥80% compared with traditional FFT, and the single detection time is ≤12 ms.

[0012] Further, the embedded main control unit uses an STM32L431 single-chip microcomputer to run a lightweight adaptive threshold algorithm; first, the DAQ collected data is filtered at 50Hz power frequency, then the peak value and variance characteristics of the magnetic flux leakage signal are extracted, the threshold value is dynamically adjusted based on the undamaged signal baseline, and the elevator running gap is adapted without affecting the elevator control logic.

[0013] Further, all wireless transmitting function units are packaged in an embedded shell with a size of ≤150 mm×80 mm×50 mm, and the shell is connected to the external cable through a waterproof quick connector to realize tool-free disassembly and assembly.

[0014] Further, the upper permanent magnet and the lower permanent magnet in the permanent magnet excitation unit are provided with an anti-corrosion coating on the surface to prolong the service life in a humid environment.

[0015] The beneficial effects of the above-mentioned application are as follows: The low-cost armature-free embedded elevator steel wire rope damage intelligent detection device of the application uses the elevator base as the magnetic circuit return path through the armature-free design, eliminates the traditional C-shaped or U-shaped armature, reduces the overall cost to less than 1 / 10 of the traditional armature system, and greatly reduces the equipment cost and installation load.

[0016] The low-cost embedded elevator steel wire rope damage intelligent detection device without armature of the application adopts a flexible circuit board to fix a Hall sensor array with a non-magnetic clamp, realizes a constant gap of ≤0.5 mm between a patch Hall element and a steel wire rope surface, cooperates with a full-range circumferential arrangement, achieves non-blind area magnetic leakage signal collection, and ensures a high detection rate of damages such as broken wires, wear and tear, corrosion and the like.

[0017] The low-cost embedded elevator steel wire rope damage intelligent detection device without armature of the application is provided with a lightweight adaptive threshold algorithm, can complete damage identification in real time during an elevator running gap, cooperates with real-time data transmission and local cache functions of a wireless communication unit, realizes 24 h online monitoring, and guarantees detection continuity.

[0018] The low-cost embedded elevator steel wire rope damage intelligent detection device without armature of the application has a shell size of ≤150 mm×80 mm×50 mm and a weight of ≤2 kg, can be directly embedded at the bottom of an elevator or the top of a car, realizes tool-free disassembly and assembly through a waterproof quick connector, does not need additional supports or modification, and is suitable for diversified installation requirements of existing and newly-built elevators.

[0019] The low-cost embedded elevator steel wire rope damage intelligent detection device without armature of the application uses a permanent magnet corrosion-resistant coating to ensure detection accuracy and equipment service life under different environmental temperatures and humid conditions, and further expands the applicable scenarios of the device. BRIEF DESCRIPTION OF DRAWINGS

[0020] The drawings accompanying the specification of the application form a part of the application and serve to further understand the application. The schematic embodiments of the application and the description thereof are used to explain the application and do not constitute an improper limitation on the application.

[0021] Figure 1 is a low-cost embedded elevator steel wire rope damage detection device according to one or more embodiments of the application; Figure 2 is a front view of a low-cost embedded elevator steel wire rope damage detection device according to one or more embodiments of the application; Figure 3 is a perspective view of a low-cost embedded elevator steel wire rope damage detection device according to one or more embodiments of the application; Figure 4 is a side view of a low-cost embedded elevator steel wire rope damage detection device according to one or more embodiments of the application; Figure 5 is a combination schematic view of a Hall sensor and a permanent magnet excitation structure according to one or more embodiments of the application; Figure 6 is a schematic view of a lower permanent magnet according to one or more embodiments of the application; Figure 7 is a schematic diagram of the upper permanent magnet according to one or more embodiments of the present application; Figure 8 is a schematic diagram of the leakage magnetic signal acquisition module according to one or more embodiments of the present application.

[0022] In the figure: 100. Elevator base; 200. Lower permanent magnet; 300. Leakage magnetic signal sending module; 400. Upper permanent magnet; 500. Elevator traction steel wire rope; 600. Elevator traction sheave; 700. Leakage magnetic signal acquisition module; 110. Traction sheave base; 120. Elevator base ferrous return structure; 210. Lower permanent magnet plate; 220. Pin hole; 230. Steel wire rope hole; 410. Upper permanent magnet plate; 420. Pin; 430 Non-magnetic plate; 710. Flexible circuit carrier; 720. Hall sensor; 730 Circuit connection hole.

[0023] The mutual distance or size of each part is exaggerated for showing the position of each part, and the schematic diagram is only for illustration. DETAILED DESCRIPTION

[0024] It should be noted that the following detailed description is illustrative only, and is intended to provide further description in order to provide a further understanding of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0025] It should be noted that the terms used herein are only for the purpose of describing specific embodiments, and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless otherwise explicitly stated in the present application, the singular form is intended to include the plural form, and in addition, it should be understood that when the terms "comprise" and / or "include" are used in the present specification, they indicate the presence of the features, steps, operations, devices, components and / or combinations thereof.

[0026] For the convenience of description, if "upper", "lower", "left" and "right" appear in the present application, they only mean the same as the upper, lower, left and right directions of the drawing itself, and do not limit the structure, but only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application.

[0027] The terms "mount", "connect", "connection", "fix", and the like in the present application should be understood in a broad sense, for example, they can be fixed connection, or detachable connection, or integral; they can be mechanical connection, or electrical connection, or direct connection, or indirect connection through intermediate medium, or internal connection of two elements, or interaction relationship between two elements, and those skilled in the art can understand the specific meaning of the above terms in the present application according to the specific circumstances.

[0028] The preferred embodiments of the present application are described in detail below with reference to the accompanying drawings, so that the advantages and features of the present application can be more easily understood by those skilled in the art, and the protection scope of the present application can be more clearly and definitely defined.

[0029] In a typical embodiment of the present application, as shown in Figures 1-8 a low-cost embedded elevator steel wire rope damage detection device is proposed, which includes an excitation module, a magnetic flux leakage signal acquisition module 700, an elevator traction steel wire rope 500, and a traditional magnetic flux leakage detection armature structure is replaced by an iron structure of an elevator base 100, an upper permanent magnet 400 is fixed on the elevator traction sheave 600 through side bolts, and a lower permanent magnet 200 is installed on the upper and lower sides of the elevator base 100.

[0030] As shown in Figure 1 the excitation module adopts a no-armature design, and the core includes an upper permanent magnet 400 and a lower permanent magnet 200, both of which are made of permanent magnetic material and are treated with nickel plating on the surface to enhance corrosion resistance. The upper permanent magnet 400 and the lower permanent magnet 200 are fixed on the upper and lower sides of the elevator steel wire rope 500 in a manner that the N-S poles are opposite to each other, and a magnetized channel with a width of 12mm is formed in the middle for the steel wire rope 500 to pass vertically.

[0031] As shown in Figure 2 the key design is to use the metal material (Q235 steel) of the elevator base 100 as a magnetic flux return path, which saves the traditional C-shaped armature and shortens the magnetic circuit length by 40% and reduces the material cost by 60%.

[0032] In an optional embodiment, as shown in Figure 3 the lower permanent magnet 200 is fixed on the iron return circuit structure 120 of the elevator base 100 through four M6 bolts, the upper permanent magnet 400 is positioned by the cooperation of the bolt 420 and the pin hole 220 of the lower permanent magnet 200, forming a closed magnetic circuit, and the non-magnetic plate 430 (material ABS) isolates the permanent magnet from the elevator traction sheave 600 to avoid magnetic interference.

[0033] When the steel wire rope 500 passes through the magnetization channel, it is magnetized to the saturation magnetic flux density, and the magnetic field is uniformly distributed along the axial direction of the steel wire rope in the undamaged state. If there are broken wires, wear or corrosion, the local magnetic resistance will suddenly change, causing the magnetic field to leak, forming a detectable magnetic leakage field.

[0034] As shown in Figure 8 The magnetic leakage signal acquisition module 600 includes a non-armature patch Hall sensor array 720 and a flexible circuit carrier 710. Eight groups of AH3515 patch Hall elements 520 are used, each group containing 8 sensors, arranged in a linear array along the axial direction of the steel wire rope at a spacing of 2mm.

[0035] In the preferred embodiment, the flexible circuit carrier uses a polyimide substrate with a thickness of 0.125mm, and the circuit connection holes 730 are formed by laser drilling to concentrate the output signals of the 8 groups of Hall elements. The substrate can be slightly bent (bend radius ≥ 50mm) with the curvature of the steel wire rope, and can adapt to the installation requirements of steel wire ropes with different diameters (8-16mm).

[0036] In the alternative embodiment, the magnetic leakage signal acquisition module is integrated into an aluminum shielding box with dimensions of 120mm x 60mm x 30mm. The core components include a multi-channel amplifier, a synchronous analog-to-digital converter, an embedded microcontroller, and a data buffer.

[0037] The working principle of the detection device is as follows: The device is used for detecting the traction steel wire rope of the running elevator, and the device is fixed to the lower side of the traction sheave for detection: When the elevator is running, the traction sheave 600 pulls the steel wire rope 500 to move, and the steel wire rope 500 continuously passes through the magnetization channel formed by the upper permanent magnet 400 and the lower permanent magnet 200. The elevator base iron structure 120 acts as an armature, and the steel wire rope is magnetized to the saturation state. If the steel wire rope is damaged, the magnetic leakage field generated is captured by the Hall sensor array 730, transmitted to the acquisition module through the flexible circuit carrier 710; the gap between the sensor and the surface of the steel wire rope is ≤0.5mm, ensuring the signal acquisition accuracy, and the magnetic leakage signal is concentrated and transmitted to the magnetic leakage signal acquisition module through the 0.125mm thick polyimide flexible circuit carrier 710.

[0038] The acquisition module generates a subprogram based on the DAQ data fast acquisition assistant, adopts INA128 low-noise amplifiers to amplify signals, processes the signals by using 12-bit resolution ADS1256 synchronous sampling ADC, and runs a lightweight adaptive threshold algorithm by using an embedded microcontroller to complete feature extraction, thereby generating a structured data packet containing a device ID, a timestamp, and damage feature parameters; the data packet is transmitted by a magnetic flux leakage signal transmission module, is transmitted by using TLS 1.2 encryption, supports MQTT protocol connection to the cloud, and stores ≥72h data locally by using a built-in 4GB storage chip when communication is interrupted.

[0039] After the cloud analyzes the data, a MATLAB broken wire damage identification model (preprocessed by wavelet threshold denoising and decomposed by using a db4 wavelet base for 5 layers) based on the LabVIEW platform is called to complete damage identification, a detection report containing damage types, position coordinates, and severity levels is created by a result generation module, the detection report is supported to be exported in an Excel format, and a user is notified by using a visual interface and an alarm interface.

[0040] The above merely describes preferred embodiments of the present application and is not intended to limit the present application. Various modifications and changes can be made by those skilled in the art based on the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. An elevator steel wire rope magnetic flux leakage detection device based on a non-clapper structure, characterized by, The application relates to a magnetic leakage signal detection system for elevator steel wire ropes. The application comprises: An excitation module which replaces a traditional magnetic leakage detection armature structure with an elevator iron structure; the upper and lower permanent magnets are fixed on the two sides of an elevator steel wire rope in an N-S pole opposite mode to form a magnetized channel for the steel wire rope; the steel wire rope is magnetized to a saturation magnetic flux density; when the steel wire rope is broken, worn or corroded, a local magnetic resistance mutation generates a magnetic leakage field; A magnetic leakage signal acquisition module which comprises a no-armature patch type Hall sensor array and a flexible circuit carrier; the no-armature patch type Hall sensor array is composed of multiple groups of patch Hall elements, each group of patch Hall elements is arranged in a linear array along the axial direction of the steel wire rope, and is arranged on the four sides of the steel wire rope respectively, and the whole group surrounds the outer periphery of the steel wire rope; the flexible circuit carrier is a bendable polyimide substrate which is used for concentrating and leading out the output signals of the patch Hall elements; A magnetic leakage signal acquisition module which realizes a data acquisition task based on a DAQ data rapid acquisition assistant, generates a data acquisition subprogram by configuring data types, sampling devices, sampling types and sampling parameters, and can output sampling data without programming; A magnetic leakage signal processing module which adopts a wavelet threshold denoising method to decompose original data into wavelet decomposition coefficients at different scales, and quantizes the wavelet coefficients at different scales of the signals according to a threshold function to achieve the purpose of inhibiting and removing damage noise; A damage identification module which transplants an identification model into a LabVIEW program block diagram by calling a MATLAB script VI, realizes damage identification and outputs results based on a LabVIEW platform and a trained broken wire damage identification model in MATLAB; A result generation module which writes and modifies a detection report by calling a report creation, adding a report file and a disposal report function in LabVIEW, and outputs a steel wire rope defect type, position and severity; A magnetic leakage signal sending module which is installed on the side of an elevator upper support, is used for wirelessly receiving structured data sent by the magnetic leakage signal acquisition module, and forwards the structured data to the result generation module through a standard interface.

2. The elevator steel wire rope magnetic flux leakage detection device based on a non-clapper structure according to claim 1, characterized in that: The magnetic leakage signal acquisition module is internally provided with a power management unit which is used for uniformly supplying power to an amplifier, an analog-to-digital converter, a microcontroller and a wireless unit.

3. The apparatus of claim 1, wherein, The permanent magnet excitation unit uses an elevator base as part of a magnetic flux return path, thereby omitting a traditional C-shaped or U-shaped armature.

4. The apparatus of claim 1, wherein, The no-armature patch type Hall sensor array comprises at least two groups of linearly arranged patch Hall elements which are symmetrically arranged on the two sides of the steel wire rope in the radial direction, and the gap between the patch Hall elements and the surface of the steel wire rope is less than or equal to 0.5 mm. The patch Hall elements are welded on a flexible circuit board, the flexible circuit board is fixed on the outer periphery of the steel wire rope through a non-magnetic clamp, all-around non-blind area detection is realized, and the installation position does not affect the normal operation of the elevator.

5. The apparatus of claim 1, wherein, The leakage magnetic signal processing module adopts db4 wavelet base function for 5-layer wavelet decomposition, adopts hard threshold quantization processing for high-frequency noise layer, adopts soft threshold quantization processing for low-frequency signal layer, and cooperates with a multi-channel amplifier and a synchronous analog-digital converter to realize a signal-to-noise ratio of ≥60 dB.

6. The apparatus of claim 1, wherein, The embedded main control unit runs light, cooperates with the elevator control module, and does not affect the normal operation logic of the elevator. The embedded main control unit (STM32L431 single-chip microcomputer) in the leakage magnetic signal acquisition module is used to coordinate the work of the multi-channel amplifier, the synchronous analog-digital converter and the data buffer, run a light adaptive threshold algorithm to complete leakage magnetic signal feature extraction, and generate structured data.

7. The apparatus of claim 1, wherein, The wireless receiving and sending function unit is packaged in the same embedded shell, the size of the shell is ≤150 mm×80 mm×50 mm, and the waterproof quick connector is connected with the external cable to realize tool-free disassembly and assembly.

8. The elevator steel cord magnetic flux leakage detection apparatus without the clapper structure according to claim 1, characterized by, The upper permanent magnet and the lower permanent magnet in the permanent magnet excitation unit are provided with an anti-corrosion coating on the surface, so as to prolong the service life of the permanent magnet in a humid environment.

9. The elevator steel cord magnetic flux leakage detection apparatus without the clapper structure according to any one of claims 1 to 8, characterized by, The device is directly embedded in the elevator base or the top of the car through the design without a clapper, and does not need an additional bracket for installation.

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