Full-intelligent steel wire rope detection system and method

Abstract

The invention discloses a full-intelligent steel wire rope detection system which comprises a rack, a mobile platform, an inclination angle adjusting mechanism, a detection probe assembly, an automatic code spraying device, an encoder assembly, a central control platform and a remote center, the mobile platform is installed on the rack and comprises a first power mechanism and a mobile seat, and the detection probe assembly is hinged to the mobile seat through a first hinge shaft; the inclination angle adjusting mechanism is hinged to the detection probe assembly through a second hinge shaft and hinged to the movable base through a third hinge shaft. The automatic code spraying device is mounted on the moving seat; the encoder assembly is installed on the moving base and makes contact with the steel wire rope. The central control platform is connected with a remote center through a wireless transmission module. The steel wire rope is magnetized through the detection probe assembly, the leakage magnetic field outside the steel wire rope is detected, the inclination angle of the detection probe assembly is flexibly adjusted through the inclination angle adjusting mechanism, and automation and intellectualization of the detection process are achieved through cooperative work of the central control platform and the remote center.

Description

Technical Field

[0001] This invention belongs to the field of magnetic flux leakage detection technology, and more specifically, relates to a fully intelligent steel wire rope detection system and method. Background Technology

[0002] In modern industrial production and transportation, wire ropes, as important mechanical transmission and load-bearing components, are widely used in various equipment and systems, such as cranes, elevators, mine hoists, port loading and unloading equipment, and cable cars. The performance and reliability of wire ropes directly affect the safe operation and production efficiency of equipment. However, during long-term use, wire ropes are affected by various factors, leading to defects such as wear, broken wires, deformation, and corrosion. If these defects are not detected and addressed in a timely manner, they may cause serious safety accidents, resulting in huge economic losses and casualties. Therefore, regular and accurate inspection of wire ropes is particularly important.

[0003] Currently, the testing technology and equipment for steel wire ropes have made some progress in the market, but there are still many problems and shortcomings in practical applications.

[0004] Traditional wire rope inspection methods primarily rely on manual visual inspection and manual measuring tools. Manual visual inspection mainly involves inspectors visually observing the surface of the wire rope for wear, broken wires, etc., but this method has obvious limitations. First, manual inspection is highly subjective; different inspectors have varying experience and judgment standards, easily leading to inconsistent test results. Second, manual inspection can only observe obvious surface defects, making it difficult to detect internal defects, minute defects, and defects in hidden areas. Furthermore, manual inspection is inefficient and unsuitable for inspecting wire ropes over long distances in complex environments.

[0005] With the development of technology, some physical principle-based testing technologies have been gradually applied to the field of wire rope inspection, such as magnetic particle testing, ultrasonic testing, and eddy current testing. Magnetic particle testing utilizes the leakage magnetic field at defects on the wire rope surface to attract magnetic powder, thereby revealing the shape and location of the defects. However, magnetic particle testing requires coating the wire rope surface with magnetic powder, making the process cumbersome, requiring high environmental conditions, susceptible to external interference, and resulting in low testing efficiency. Ultrasonic testing detects defects by detecting the reflection, refraction, and scattering phenomena caused by ultrasonic waves encountering defects as they propagate within the wire rope. However, ultrasonic testing requires high operator skills, and interpreting ultrasonic signals can be difficult for complex defect morphologies and structures. Eddy current testing utilizes the principle of electromagnetic induction, detecting changes in eddy currents to determine the condition of the wire rope. While eddy current testing offers a certain advantage in detection speed, its ability to detect deep defects in wire ropes is limited, and it is easily affected by the surface condition of the wire rope and environmental factors.

[0006] Existing technologies for inspecting multi-row parallel synchronous operating wire ropes are quite limited. Multi-row parallel synchronous operating wire ropes are a special mechanical system that achieves load balance through the synchronous traction of multiple rows of wire ropes, commonly found in scenarios such as double-hook electric hoists and mine transportation. The operating characteristics of this type of wire rope place higher demands on inspection equipment. Currently, intelligent inspection equipment for multi-row parallel synchronous operating wire ropes on the market typically increases the number of inspection devices, using a quantitative accumulation method to meet intelligent inspection functions. This method of accumulating inspection equipment has several problems. First, the equipment utilization rate is low; a large number of inspection devices cannot fully utilize their functions in actual use, leading to resource waste. Second, energy consumption is high; multiple inspection devices operating simultaneously consume a large amount of energy, increasing inspection costs. Furthermore, the installation and maintenance of this type of accumulated inspection equipment is relatively complex, requiring more manpower and resources. Moreover, coordination and synchronization between multiple inspection devices also present difficulties, easily leading to inconsistent inspection data, duplicate inspections, or missed inspections, affecting the accuracy and reliability of the inspection results. Summary of the Invention

[0007] In view of the above-mentioned defects or improvement needs of the existing technology, the present invention provides a fully intelligent steel wire rope detection system and method, which can perform efficient, accurate and intelligent detection of steel wire ropes.

[0008] To achieve the above objectives, according to one aspect of the present invention, a fully intelligent wire rope inspection system is provided, comprising a frame, a moving platform, a tilt adjustment mechanism, an inspection probe assembly, an automatic inkjet printer, an encoder assembly, a central control platform, and a remote control center, wherein: The mobile platform is mounted on the frame and includes a first power mechanism and a mobile base. The first power mechanism is connected to the mobile base to drive the mobile base to move linearly to approach and move away from the wire rope. The detection probe assembly is hinged to the movable seat via a first hinge shaft, and is used to magnetize and detect magnetic leakage of the wire rope, and transmit the magnetic leakage detection data to the central control platform. The tilt adjustment mechanism is hinged to the detection probe assembly via a second hinge shaft, and the tilt adjustment mechanism is hinged to the movable seat via a third hinge shaft, so as to adjust the tilt angle of the detection probe assembly to adapt to wire ropes with various tilt angles. The automatic inkjet marking device is installed on the mobile base and is used to receive instructions from the central control platform to mark the defective parts of the wire rope detected by the detection probe assembly. The encoder assembly is mounted on the movable base and in contact with the wire rope to collect the wire rope movement data and transmit the wire rope movement data to the central control platform. The central control platform is connected to the remote center via a wireless transmission module.

[0009] Preferably, the first power mechanism is an electric push rod, the movable seat is equipped with rollers, and the frame supports the rollers.

[0010] Preferably, the tilt adjustment mechanism includes a first connecting rod, a threaded sleeve, and a second connecting rod. The first end of the first connecting rod is provided with a first external thread, and the first end of the threaded sleeve is provided with a first internal thread that mates with the first external thread. The first connecting rod is threaded to the first end of the threaded sleeve. The first end of the second connecting rod is provided with a second external thread, the second external thread having the opposite rotation direction to the first external thread. The second end of the threaded sleeve is provided with a second internal thread that mates with the second external thread, and the second connecting rod is threaded to the second end of the threaded sleeve. The second end of the first connecting rod is hinged to the detection probe assembly via the second hinge axis, and the second end of the second connecting rod is hinged to the movable seat via the third hinge axis.

[0011] Preferably, the detection probe assembly includes a mounting frame, a second power mechanism, a magnetizer, a magnetic sensitive element, and a wear-resistant element. The mounting frame is mounted on the movable base. The magnetizer has a split structure and includes a first magnet and a second magnet. The first magnet is mounted on the mounting frame. The second power mechanism is mounted on the mounting frame and connected to the second magnet to drive the second magnet to move, thereby allowing the second magnet to move closer to and further away from the first magnet to accommodate steel wire ropes of different diameters. The magnetic sensitive element is mounted on the mounting frame and extends into the magnetizer to detect leakage magnetic fields outside the steel wire rope. The wear-resistant element is mounted on the magnetizer and located between the magnetic sensitive element and the steel wire rope to protect the magnetic sensitive element.

[0012] Preferably, the mounting bracket is mounted on the movable seat via two parallel guide shafts A, and a sliding bearing is provided between the mounting bracket and each of the guide shafts A, wherein the guide shafts A are perpendicular to the output shaft of the second power mechanism.

[0013] Preferably, an elastic buffer mechanism is provided between the mounting bracket and the movable seat to buffer the axial movement of the mounting bracket along the guide shaft A.

[0014] Preferably, the encoder assembly includes a connecting bracket and an encoding wheel and an encoding measurement unit mounted on the connecting bracket. The connecting bracket is mounted on the movable base. The encoding wheel is in contact with the steel wire rope to rotate during the movement of the steel wire rope. The encoding measurement unit is connected to the encoding wheel to collect the rotation data of the encoding wheel.

[0015] Preferably, the central control platform includes a cabinet and a data acquisition and transmission module, a data analysis and processing module, and a central processing computer installed in the cabinet. The data acquisition and transmission module is used to receive the magnetic flux leakage data of the steel wire rope detected by the detection probe assembly and transmit it to the data analysis and processing module. The data analysis and processing module analyzes and processes the magnetic flux leakage data and then transmits it to the central processing computer, which refines, transforms, and stores the magnetic flux leakage data.

[0016] Preferably, the system also includes a monitoring device, which uses high-speed industrial cameras with multiple orientations to take matrix photos and analyzes and judges the operating status of the equipment through visual algorithms, thereby effectively controlling and correcting the movement.

[0017] According to another aspect of the present invention, a detection method for the fully intelligent wire rope detection system is also provided, comprising the following steps: 1) The first power mechanism drives the moving seat to move in a straight line to approach the wire rope. The wire rope enters the detection probe assembly through the opening on the detection probe assembly so that the detection probe assembly can magnetize the wire rope. 2) Adjust the tilt angle of the detection probe assembly through the tilt angle adjustment mechanism to adapt the detection probe assembly to the tilt angle of the steel wire rope to be inspected; 3) As the wire rope moves, the detection probe assembly performs magnetic leakage detection on the wire rope; 4) During the magnetic flux leakage detection process, the detection probe assembly transmits the magnetic flux leakage detection data to the central control platform, while the encoder assembly collects the wire rope movement data and transmits it to the central control platform. 5) The central control platform analyzes and processes the leakage magnetic data. If the central control platform finds defects on the wire rope after analysis and processing, it sends an instruction to the automatic inkjet printing device installed on the mobile seat, and the automatic inkjet printing device marks the defective parts with inkjet printing. 6) The central control platform sends the magnetic flux leakage detection data and analysis results to the remote center.

[0018] In summary, compared with the prior art, the above-described technical solutions conceived by this invention can achieve the following beneficial effects: 1) The fully intelligent wire rope detection system of the present invention magnetizes the wire rope through a detection probe assembly and detects the leakage magnetic field outside the wire rope. This detection method can effectively identify minute defects inside and on the surface of the wire rope. Compared with traditional detection methods, the leakage magnetic detection technology has higher sensitivity and resolution and can detect more subtle defects, such as broken wires, wear, and corrosion, thereby significantly improving the accuracy of detection. This high-precision detection capability is crucial for ensuring the safe operation of the wire rope.

[0019] 2) The fully intelligent wire rope inspection system of this invention features a tilt adjustment mechanism that allows for flexible adjustment of the tilt angle of the inspection probe assembly. This not only meets the inspection requirements of multiple rows of parallel and synchronously operating wire ropes but also adapts to wire rope inspection tasks under various complex working conditions. The system can quickly adjust the angle of the inspection probe assembly through the tilt adjustment mechanism, ensuring the stability and accuracy of the inspection. This high degree of adaptability greatly expands the system's application scenarios and improves its practicality in different industrial environments.

[0020] 3) The fully intelligent wire rope inspection system of this invention achieves automation and intelligence in the inspection process through the collaborative work of a central control platform and a remote center. The central control platform receives and analyzes the magnetic leakage data transmitted by the inspection probe assembly. Once a defect in the wire rope is detected, the central control platform can automatically send instructions to the automatic inkjet marking device to mark the defective area. This automated inspection process not only improves inspection efficiency but also reduces the impact of human factors on the inspection results. Simultaneously, the inspection data and analysis results are sent to the remote center via a wireless transmission module, enabling real-time monitoring and remote management of the inspection data. This intelligent design allows the system to better integrate into modern industrial automation systems, providing strong support for equipment maintenance and management.

[0021] 4) The fully intelligent wire rope inspection system of this invention uses an automatic inkjet marking device to mark defective areas, allowing operators to quickly locate and address defects, thus preventing safety accidents caused by undetected defects. Simultaneously, the system's high-precision detection capabilities and automated processes ensure the accuracy and reliability of the inspection results, reducing the possibility of misjudgments and missed detections. Attached Figure Description

[0022] Figure 1 , Figure 2 These are perspective views of the invention from different angles; Figure 3 for Figure 1 Enlarged view of point A in the middle; Figure 4 , Figure 5 This is a three-dimensional schematic diagram of the detection probe assembly in this invention from different perspectives; In all the accompanying drawings, the same reference numerals denote the same technical features, specifically: 1. Frame; 2. Moving platform; 21. First power mechanism; 22. Moving seat; 23. Roller; 221. Long strip hole; 24. Third hinge shaft; 3. Tilt adjustment mechanism; 4. Detection probe assembly; 5. Inkjet printer; 6. Central control platform; 7. Hinge seat; 401. First hinge shaft; 402. Second hinge shaft; 31. First connecting rod; 32. Second connecting rod; 33. Threaded sleeve; 41. Probe bracket; 42. Second power mechanism; 431. First magnet; 432. Second magnet; 433. First connecting shell; 434. Second connecting shell; 44. Guide shaft A; 45. Sliding bearing; 46. Elastic buffer mechanism; 461. Bolt; 462. First compression spring; 463. Second compression spring; 47. Guide shaft B. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the 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 merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0024] Reference Figures 1-5 The fully intelligent wire rope inspection system includes a frame 1, a mobile platform 2, an angle adjustment mechanism 3, an inspection probe assembly 4, an automatic inkjet printer 5, an encoder assembly, a central control platform 6, and a remote control center.

[0025] The mobile platform 2 is mounted on the frame 1. The mobile platform 2 includes a first power mechanism 21 and a mobile base 22. The first power mechanism 21 is connected to the mobile base 22 to drive the mobile base 22 to move linearly to approach and move away from the wire rope. The detection probe assembly 4 is hinged to the movable seat 22 via the first hinge shaft 401, and is used to magnetize and detect magnetic leakage of the wire rope, and transmit the magnetic leakage detection data to the central control platform 6. The tilt adjustment mechanism 3 is hinged to the detection probe assembly 4 via the second hinge shaft 402, and the tilt adjustment mechanism 3 is hinged to the moving seat 22 via the third hinge shaft 24, so as to adjust the tilt angle of the detection probe assembly 4 to adapt to wire ropes with various tilt angles. The automatic inkjet printing device 5 is installed on the movable base 22 and is used to receive instructions from the central control platform 6 to mark the defective parts of the wire rope detected by the detection probe assembly 4. The encoder assembly is mounted on the movable base 22 and in contact with the wire rope to collect the wire rope movement data and transmit the wire rope movement data to the central control platform 6. The central control platform 6 is connected to the remote center via a wireless transmission module.

[0026] The detection probe assembly 4 saturates the wire rope with magnetization. When the magnetic lines of force encounter cross-sectional losses or localized damage in ferromagnetic materials, they overflow onto the surface, forming a leakage magnetic field. This means that the system can not only detect surface wear and corrosion, but also effectively detect fractures in the core rope inside the wire rope.

[0027] In actual working conditions, steel wire ropes are often not vertical or horizontal, but have a specific tilt angle, which may vary with the load. This invention introduces a tilt adjustment mechanism 3, which hinges the detection probe assembly 4 via a second hinge shaft 402 and the moving seat 22 via a third hinge shaft 24. This double-hinged linkage design constructs a highly flexible attitude adjustment system. It can flexibly adjust the pitch angle of the detection probe assembly 4 according to the actual spatial angle of the steel wire rope under test, achieving parallel and flexible docking between the detection probe assembly 4 and the steel wire rope. This attitude matching is crucial. If there is an angle between the detection probe assembly 4 and the steel wire rope, it will cause drastic fluctuations in the lift-off value between the magnetic sensing element inside the probe and the surface of the steel wire rope, generating huge noise signals, and even causing jamming or probe damage. By keeping the attitude of the detection probe assembly 4 consistent with that of the steel wire rope, the stability of the detection and the high signal-to-noise ratio of the signal are ensured.

[0028] Furthermore, the hardware integration of the detection probe assembly 4, central control platform 6, automatic inkjet printer 5, and encoder assembly enables real-time signal processing. In the system, the detection probe assembly 4 is responsible for acquiring magnetic leakage signals, while the encoder assembly, in contact with the wire rope, acquires motion data (velocity and displacement). The central control platform 6 receives these two data streams and performs spatiotemporal synchronous fusion. By combining the magnetic leakage signal with the encoder data, the central control platform 6 can accurately calculate the physical location and equivalent size of the defect. This multi-sensor fusion technology is the foundation for achieving quantitative detection.

[0029] The automatic inkjet marking device 5 marks the defective areas of the wire rope detected by the detection probe assembly 4. When the detection probe assembly 4 detects a defect in the wire rope, the central control platform immediately calculates the location of the defect and triggers inkjet marking the moment the defect passes the automatic inkjet marking device 5 (the relative position of the automatic inkjet marking device 5 and the detection probe assembly 4 is known, therefore the location of the automatic inkjet marking device 5 and the detected defect is known). This function instantly converts the digital defect into a physical mark. For later maintenance, simply locate the location marked by the ink from the automatic inkjet marking device 5 to perform the operation.

[0030] The central control platform 6, designed to connect to a remote center via a wireless transmission module, upgrades the device from a standalone tool into a smart terminal for the Industrial Internet of Things (IIoT). Wire rope operation sites are typically accompanied by high noise levels, oil contamination, dust, and even the risk of falling objects from heights. Through wireless transmission, operators can monitor the process from a safe area (remote center) away from the site, truly realizing the vision of unattended or minimally staffed automated operations.

[0031] Furthermore, the first power mechanism 21 is an electric push rod, and rollers 23 are mounted on the movable seat 22, with the frame 1 supporting the rollers 23. Using an electric push rod as the first power mechanism 21 enables precise linear movement control of the movable seat 22. The electric push rod has high stroke accuracy and stability, ensuring the movement accuracy of the movable seat 22 when approaching or moving away from the wire rope. The rolling friction of the rollers 23 is much less than the sliding friction, thereby reducing energy loss and improving the system's movement efficiency. Simultaneously, the rolling motion of the rollers 23 ensures the smooth movement of the movable seat 22, avoiding vibration or shaking caused by excessive friction, thus improving the stability of the detection probe assembly 4 during operation.

[0032] Furthermore, the tilt adjustment mechanism 3 can adopt a conventional electric push rod to achieve automatic tilt adjustment; preferably, the tilt adjustment mechanism 3 includes a first connecting rod 31, a threaded sleeve 33, and a second connecting rod 32. The first end of the first connecting rod 31 is provided with a first external thread, and the first end of the threaded sleeve 33 is provided with a first internal thread that mates with the first external thread. The first connecting rod 31 is threaded to the first end of the threaded sleeve 33. The first end of the second connecting rod 32 is provided with a second external thread, the second external thread having the opposite rotation direction to the first external thread. The second end of the threaded sleeve 33 is provided with a second internal thread that mates with the second external thread, and the second connecting rod 32 is threaded to the second end of the threaded sleeve 33.

[0033] The second end of the first connecting rod 31 is hinged to the detection probe assembly 4 via the second hinge shaft 402, and the second end of the second connecting rod 32 is hinged to the movable seat 22 via the third hinge shaft 24.

[0034] By turning the threaded sleeve 33, the relative distance between the first connecting rod 31 and the second connecting rod 32 and the tilt angle of the first connecting rod 31 and the second connecting rod 32 can be adjusted, thereby allowing the first connecting rod 31 to drive the detection probe assembly 4 to rotate around the center line of the first hinge shaft 401.

[0035] The tilt adjustment mechanism 3, through the combination of the first connecting rod 31, the threaded sleeve 33, and the second connecting rod 32, enables precise adjustment of the tilt angle of the detection probe assembly 4. This design allows the detection probe assembly 4 to maintain optimal contact with the wire rope at different tilt angles, thereby ensuring the accuracy and reliability of the detection. Especially in applications with multiple rows of parallel and synchronously operating wire ropes, the tilt angle of the wire rope may change due to the operating conditions of the equipment. The tilt adjustment mechanism 3 can quickly adapt to these changes, ensuring that the detection probe assembly is always in the optimal detection position.

[0036] Furthermore, the detection probe assembly 4 includes a mounting frame 41, a second power mechanism 42, a magnetizer, a magnetic sensitive element, and a wear-resistant element. The mounting frame 41 is mounted on the movable base 22. The magnetizer has a split structure and includes a first magnet 431 and a second magnet 432. The first magnet 431 is mounted on the mounting frame 41, and the second power mechanism 42 is mounted on the mounting frame 41. The second power mechanism 42 is connected to the second magnet 432 and is used to drive the second magnet 432 to move, thereby allowing the second magnet 432 and the first magnet 431 to move closer and further apart to accommodate steel wire ropes of different diameters. The magnetic sensitive element is mounted on the mounting frame 41 and extends into the magnetizer to detect the leakage magnetic field outside the steel wire rope. The wear-resistant element is mounted on the magnetizer and located between the magnetic sensitive element and the steel wire rope to protect the magnetic sensitive element.

[0037] The first magnet 431 and the second magnet 432 can move closer to or further away from each other. This design allows the detection probe assembly 4 to adapt to steel wire ropes of different diameters without requiring replacement or complex adjustments. Furthermore, when they are far apart, they form an opening, facilitating the entry of the steel wire rope into the detection probe assembly 4. The magnetic sensing element enables high-precision detection of internal and surface defects in the steel wire rope. Wear-resistant elements prevent direct contact between the first magnet 431 and the second magnet 432 and the steel wire rope. This design not only protects the magnetizer from wear on the steel wire rope surface but also reduces performance degradation caused by long-term friction.

[0038] Furthermore, the mounting bracket 41 is mounted on the movable seat 22 via two parallel guide shafts A44, and a sliding bearing 45 is respectively provided between the mounting bracket 41 and each guide shaft A44. The guide shafts A44 are perpendicular to the output shaft of the second power mechanism 42. Unevenness (such as strands) on the surface of the wire rope or slight changes in diameter can generate high-frequency impact forces on the probe. The sliding bearings 45 provide a contact interface with a low coefficient of friction, allowing the mounting bracket 41 to slide sensitively on the guide shafts A44. This means that when the position of the wire rope shifts slightly, the detection probe assembly can smoothly follow the movement instead of getting stuck due to excessive static friction, preventing hard collisions or excessive compression between the probe and the wire rope.

[0039] Furthermore, an elastic buffer mechanism 46 is provided between the mounting bracket 41 and the movable seat 22 to buffer the movement of the mounting bracket 41 along the axial direction of the guide shaft A44 (the axial direction of the guide shaft A44 is parallel to the Z-axis).

[0040] During high-speed operation, wire ropes often experience severe lateral vibration, whipping effects, and periodic vibrations caused by their own twisting. The elastic buffer mechanism 46, through elastic deformation, converts instantaneous impact kinetic energy into elastic potential energy or dissipates heat, significantly mitigating peak impact force. Wire ropes are not ideal straight cylinders; their surfaces exhibit strand ripples and diameter tolerances. The elastic buffer mechanism 46 provides the mounting bracket 41 with a floating degree of freedom along the guide shaft A44. When the wire rope experiences slight radial runout, the elastic mechanism utilizes its restoring force to push the detection probe assembly 4 to remain close to or maintain a constant distance from the wire rope, ensuring the magnetic sensing element maintains the set lift-off value. This flexible follow-up characteristic of the elastic buffer mechanism 46 effectively suppresses lift-off noise caused by the runout of the detection probe assembly 4. Without buffering, the probe would vibrate erratically, causing severe fluctuations in the baseline signal, which the system could easily misinterpret as wire breakage or wear signals. Therefore, this design filters out mechanical noise at the physical level, providing the backend data analysis and processing module with cleaner and more authentic raw data.

[0041] Furthermore, the elastic buffer mechanism 46 includes a bolt 461, a first compression spring 462, and a second compression spring 463. The bolt 461 passes through the probe bracket 41, and the bolt tail of the bolt 461 is threaded onto the probe bracket 41. The first compression spring 462 is located between the probe bracket 41 and the movable seat 22, and the second compression spring 463 is located between the bolt head of the bolt 461 and the movable seat 22. When the wire rope experiences radial jump or a slight change in diameter due to strand waves, the first compression spring 462 and the second compression spring 463 provide bidirectional elastic buffering for the probe bracket 41 and the magnetizer, using the restoring force to keep the detection probe assembly 4 in close contact with and follow the movement of the wire rope. In addition, the first compression spring 462 and the second compression spring 463, through elastic deformation, can convert the instantaneous mechanical impact kinetic energy of the wire rope into elastic potential energy, which greatly suppresses the peak impact force and avoids hard collisions. Specifically, when the wire rope presses the detection probe assembly 4 in the first direction, the first compression spring 462 is compressed; when the wire rope presses the detection probe assembly 4 in the second direction opposite to the first direction, the second compression spring 463 is compressed, thereby forming an effective buffer.

[0042] Furthermore, the probe bracket 41 is equipped with multiple parallel guide shafts B47, which are parallel to the output shaft of the second power mechanism 42. The first magnet 431 and the second power mechanism 42 are both mounted on the first connecting shell 433, and the first connecting shell 433 is slidably mounted on each of the guide shafts B47; The second magnet 432 is mounted on the second connecting shell 434, which is slidably mounted on each of the guide shafts B47. After the second power mechanism 42 drives the second magnet 432 closer to the first magnet 431 to confine the wire rope within the magnetizer, the second power mechanism 42 and the magnetizer as a whole can move along the guide shaft B47 (the axial direction of the guide shaft B is parallel to the Y-axis) to accommodate the jumping of the wire rope, since the wire rope is prone to jumping during movement.

[0043] Guide shaft B47 and guide shaft A44 are set perpendicular to each other in space, respectively taking over the degrees of freedom of the detection probe assembly 4 in the horizontal and vertical directions.

[0044] When the wire rope wobbles laterally, the first connecting shell 433 and the second connecting shell 434, as a whole, are pushed by the lateral force of the wire rope to slide axially along the guide shaft B47, achieving passive centering and eliminating lateral hard friction. When the wire rope bounces radially, the impact force drives the entire mounting frame 41 to overcome the resistance of the elastic buffer mechanism 46 and slide axially along the guide shaft A44. This combination of guide shaft B47 sliding and guide shaft A44 sliding buffer effectively gives the detection probe assembly a two-dimensional floating plane perpendicular to the wire rope axis. Regardless of the direction of the wire rope's bounce, the detection probe assembly can maintain its position by adjusting its posture, thereby filtering out vibration noise from a mechanical and physical perspective, ensuring the dynamic stability of the lift-off value between the magnetic sensing element and the wire rope surface, and providing a stable detection foundation for subsequent high-precision magnetic flux leakage detection.

[0045] Furthermore, the encoder assembly includes a connecting bracket and an encoding wheel and an encoding measurement unit mounted on the connecting bracket. The connecting bracket is mounted on the movable seat 22. The encoding wheel is in contact with the steel wire rope to rotate during the movement of the steel wire rope. The encoding measurement unit is connected to the encoding wheel to collect the rotation data of the encoding wheel. By having the encoding wheel in contact with the steel wire rope, the linear displacement of the steel wire rope is converted into the angular displacement of the encoding wheel through friction transmission, and then converted into a digital pulse signal by the encoding measurement unit. This direct contact measurement method can minimize slippage and accumulated errors, providing a high-precision length measurement reference. The central control platform 6 can synchronize and fuse the magnetic flux leakage detection data with the steel wire rope movement data in real time. Relying on the precise measurement of the encoder, the system can send instructions before the defect point passes the nozzle of the automatic inkjet printer, ensuring that the ink is accurately sprayed at the defect location without misalignment or missed areas.

[0046] Furthermore, the central control platform includes a cabinet and a data acquisition and transmission module, a data analysis and processing module, and a central processing computer installed within the cabinet. The data acquisition and transmission module receives the magnetic flux leakage data of the wire rope detected by the detection probe assembly 4 and transmits it to the data analysis and processing module. The data analysis and processing module analyzes and processes the magnetic flux leakage data and then transmits it to the central processing computer, which refines, transforms, and stores the data. The data acquisition and transmission module is responsible for the underlying high-speed sampling and A / D conversion, while the data analysis and processing module is responsible for preliminary signal cleaning and feature extraction. After analysis and processing, the effective data is then transmitted to the central processing computer. This layered architecture enables true parallel computing. The acquisition module focuses on not missing any pulses, the analysis module focuses on quickly identifying abnormal waveforms, and the central computer focuses on human-computer interaction and decision-making. This design ensures that the system can maintain a millisecond-level defect identification response speed even when the wire rope is running at high speed, providing timely trigger commands for the backend automatic inkjet printing device 5. As an intermediate layer, the data analysis and processing module can perform hardware-level filtering and noise reduction to eliminate high-frequency noise caused by wire rope swaying or electromagnetic interference. This significantly improves the signal-to-noise ratio of the data transmitted to the central processing computer.

[0047] Furthermore, the system also includes monitoring equipment. This equipment uses high-speed industrial cameras in multiple orientations to take matrix photos and analyzes the images using visual algorithms to determine the equipment's operating status, thereby effectively controlling and correcting deviations. Through its deviation correction function, the monitoring equipment upgrades the system from a simple signal acquisition device to an intelligent device with visual servo control capabilities. Vision-based deviation correction significantly reduces the risk of equipment failure. The introduction of this monitoring equipment significantly improves the detection accuracy, reliability, and intelligence level of the fully intelligent wire rope detection system.

[0048] According to another aspect of the present invention, a detection method for the fully intelligent wire rope detection system is also provided, comprising the following steps: 1) The first power mechanism 21 drives the moving seat 22 to move in a straight line to approach the wire rope. The wire rope enters the detection probe assembly 4 through the opening on the detection probe assembly 4 so that the detection probe assembly 4 can magnetize the wire rope.

[0049] 2) The tilt angle of the detection probe assembly 4 is adjusted by the tilt angle adjustment mechanism 3 so that the detection probe assembly 4 can adapt to the tilt angle of the wire rope to be inspected; through the coordinated work of the tilt angle adjustment mechanism 3 and the detection probe assembly 4, the detection system can accurately adapt to wire ropes with different tilt angles and diameters.

[0050] 3) The wire rope moves, and the detection probe assembly 4 performs magnetic leakage detection on the wire rope.

[0051] 4) During the magnetic flux leakage detection process, the detection probe assembly 4 transmits the magnetic flux leakage detection data to the central control platform 6, while the encoder assembly collects the wire rope movement data and transmits it to the central control platform 6.

[0052] 5) The central control platform 6 analyzes and processes the leakage magnetic data. If the central control platform 6 obtains defects on the wire rope after analysis and processing, it sends an instruction to the automatic inkjet printer 5 installed on the mobile seat 22, and the automatic inkjet printer 5 marks the defective parts with inkjet printing.

[0053] 6) The central control platform 6 sends the magnetic flux leakage detection data and analysis results to the remote center.

[0054] To achieve accurate physical marking of defect points, the detection probe assembly 4 and the automatic inkjet printer 5 maintain a fixed mounting distance L on the movable base 22. The central control platform 6 employs positioning and tracking technology based on encoder pulse counting.

[0055] In step 5), although the central control platform 6 can calculate the real-time running speed of the wire rope, v However, simply relying on time delay t ( t = L / v Using a distance-based method to trigger the automatic inkjet printer 5 for marking is not very accurate because the wire rope accelerates and decelerates during operation. This system preferably utilizes the pulse signal from the encoder assembly to achieve precise distance-based triggering of the automatic inkjet printer 5.

[0056] The central control platform 6 pre-determines the displacement δ of the wire rope represented by each pulse signal output by the encoder, and detects the fixed distance between the magnetic sensitive element of the detection probe assembly 4 and the nozzle of the automatic coding device 5. L Converted into pulse difference N delay =L / δ.

[0057] The encoder assembly's encoder wheel is in contact with the steel wire rope and rotates during movement. The encoder converts physical displacement into electrical signal pulses. Assuming that the encoder wheel generates N pulses per revolution and the circumference of the encoder wheel is C, then each encoder pulse represents a steel wire rope displacement δ=C / N (this is a known constant). The central control platform periodically (e.g., every 10 milliseconds or 50 milliseconds) reads the pulse count increment.

[0058] v = (Number of pulses sent by the encoder per unit time × δ) / unit time; The central control platform receives real-time pulse data continuously sent by the encoder component and uses its powerful data processing capabilities to perform the aforementioned calculations, thereby obtaining the real-time running speed of the wire rope. v .

[0059] When the wire rope moves at high speed, the system workflow is as follows: 1. When the magnetic sensing element in the detection probe assembly 4 detects a magnetic leakage signal (defect point), the central control platform 6 immediately reads the current encoder cumulative pulse value P. current-0 .

[0060] 2. The encoder component continuously sends real-time pulse data to the central control platform.

[0061] 3. Under high-precision requirements, system response lag needs to be considered. This is because there is a delay in the solenoid valve's action and ink flight time between the central control platform issuing the command and the automatic inkjet printer 5 actually ejecting the ink. Therefore, the central control platform 6 introduces speed compensation, which advances the actual triggering position of the automatic inkjet printer 5, ensuring that the ink coincides precisely with the moving defect point when it flies and contacts the wire rope surface. Then, when the current encoder's cumulative pulse value reaches P... current-p =P current-0 +(L- v× t latency When the central control platform triggers the automatic inkjet printer 5 to spray ink, after the set action delay time t, the ink is sprayed out. latency Then, the ink can be precisely applied to the defect points of the moving wire rope, where t latency The system action delay time is usually a fixed value in milliseconds, determined by the hardware of the central control platform and the automatic inkjet printing device, and can be measured in advance through experiments.

[0062] Furthermore, the third hinge shaft 24 is mounted on the movable seat 22 via a hinge base 7. The hinge base 7 has a connecting hole, and the movable seat 22 has an elongated hole 221. A bolt fastening device passes through the connecting hole and the elongated hole 221 to fix the hinge base 7 to the movable seat 22. The design of the elongated hole 221 actually provides a unidirectional degree of freedom of adjustment during the assembly stage. Before the final tightening of the bolts, the hinge base 7 can slide along the length of the elongated hole 221 within its range. The optimal position of the third hinge shaft 24 can be determined according to the actual natural state of the connecting rod and the detection probe assembly 4, and the posture of the detection probe assembly 4 can be adjusted to better adapt to the wire rope.

[0063] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A fully intelligent steel wire rope detection system, characterized in that, It includes a frame, a moving platform, a tilt adjustment mechanism, a detection probe assembly, an automatic inkjet printer, an encoder assembly, a central control platform, and a remote control center, among which: The mobile platform is mounted on the frame and includes a first power mechanism and a mobile base. The first power mechanism is connected to the mobile base to drive the mobile base to move linearly to approach and move away from the wire rope. The detection probe assembly is hinged to the movable seat via a first hinge shaft, and is used to magnetize and detect magnetic leakage of the wire rope, and transmit the magnetic leakage detection data to the central control platform. The tilt adjustment mechanism is hinged to the detection probe assembly via a second hinge shaft, and the tilt adjustment mechanism is hinged to the movable seat via a third hinge shaft, so as to adjust the tilt angle of the detection probe assembly to adapt to wire ropes with various tilt angles. The automatic inkjet marking device is installed on the mobile base and is used to receive instructions from the central control platform to mark the defective parts of the wire rope detected by the detection probe assembly. The encoder assembly is mounted on the movable base and in contact with the wire rope to collect the wire rope movement data and transmit the wire rope movement data to the central control platform. The central control platform is connected to the remote center via a wireless transmission module.

2. The fully intelligent wire rope detection system according to claim 1, characterized in that, The first power mechanism is an electric push rod, and the movable seat is equipped with rollers, which are supported by the frame.

3. The fully intelligent steel wire rope detection system according to claim 1, characterized in that, The tilt adjustment mechanism includes a first connecting rod, a threaded sleeve, and a second connecting rod. The first end of the first connecting rod is provided with a first external thread, and the first end of the threaded sleeve is provided with a first internal thread that mates with the first external thread. The first connecting rod is threaded to the first end of the threaded sleeve. The first end of the second connecting rod is provided with a second external thread, the second external thread having the opposite rotation direction to the first external thread. The second end of the threaded sleeve is provided with a second internal thread that mates with the second external thread, and the second connecting rod is threaded to the second end of the threaded sleeve. The second end of the first connecting rod is hinged to the detection probe assembly via the second hinge axis, and the second end of the second connecting rod is hinged to the movable seat via the third hinge axis.

4. The fully intelligent wire rope detection system according to claim 1, characterized in that, The detection probe assembly includes a mounting frame, a second power mechanism, a magnetizer, a magnetic sensitive element, and a wear-resistant element. The mounting frame is mounted on the movable base. The magnetizer has a split structure and includes a first magnet and a second magnet. The first magnet is mounted on the mounting frame, and the second power mechanism is mounted on the mounting frame and connected to the second magnet to drive the second magnet to move, thereby allowing the second magnet to move closer to and further away from the first magnet to accommodate steel wire ropes of different diameters. The magnetic sensitive element is mounted on the mounting frame and extends into the magnetizer to detect leakage magnetic fields outside the steel wire rope. The wear-resistant element is mounted on the magnetizer and located between the magnetic sensitive element and the steel wire rope to protect the magnetic sensitive element.

5. The fully intelligent wire rope detection system according to claim 4, characterized in that, The mounting bracket is mounted on the movable seat via two parallel guide shafts A, and a sliding bearing is provided between the mounting bracket and each of the guide shafts A. The guide shafts A are perpendicular to the output shaft of the second power mechanism.

6. The fully intelligent wire rope detection system according to claim 5, characterized in that, An elastic buffer mechanism is provided between the mounting bracket and the movable seat to buffer the axial movement of the mounting bracket along the guide shaft A.

7. The fully intelligent wire rope detection system according to claim 1, characterized in that, The encoder assembly includes a connecting bracket and an encoding wheel and an encoding measurement unit mounted on the connecting bracket. The connecting bracket is mounted on the movable base. The encoding wheel is in contact with the steel wire rope to rotate during the movement of the steel wire rope. The encoding measurement unit is connected to the encoding wheel to collect the rotation data of the encoding wheel.

8. The fully intelligent wire rope detection system according to claim 1, characterized in that, The central control platform includes a cabinet and a data acquisition and transmission module, a data analysis and processing module, and a central processing computer installed in the cabinet. The data acquisition and transmission module is used to receive the magnetic flux leakage data of the steel wire rope detected by the detection probe assembly and transmit it to the data analysis and processing module. The data analysis and processing module analyzes and processes the magnetic flux leakage data and then transmits it to the central processing computer, which refines, transforms, and stores the magnetic flux leakage data.

9. The fully intelligent wire rope detection system according to claim 1, characterized in that, It also includes monitoring equipment, which uses high-speed industrial cameras in multiple orientations to take matrix photos and uses visual algorithms to analyze and determine the operating status of the equipment, thereby effectively controlling and correcting the movement.

10. The detection method of the fully intelligent steel wire rope detection system according to any one of claims 1-9, characterized in that, Includes the following steps: 1) The first power mechanism drives the moving seat to move in a straight line to approach the wire rope. The wire rope enters the detection probe assembly through the opening on the detection probe assembly so that the detection probe assembly can magnetize the wire rope. 2) Adjust the tilt angle of the detection probe assembly through the tilt angle adjustment mechanism to adapt the detection probe assembly to the tilt angle of the steel wire rope to be inspected; 3) As the wire rope moves, the detection probe assembly performs magnetic leakage detection on the wire rope; 4) During the magnetic flux leakage detection process, the detection probe assembly transmits the magnetic flux leakage detection data to the central control platform, while the encoder assembly collects the wire rope movement data and transmits it to the central control platform. 5) The central control platform analyzes and processes the leakage magnetic data. If the central control platform finds defects on the wire rope after analysis and processing, it sends an instruction to the automatic inkjet printing device installed on the mobile seat, and the automatic inkjet printing device marks the defective parts with inkjet printing. 6) The central control platform sends the magnetic flux leakage detection data and analysis results to the remote center.

Images