Steel wire rope wear degree defect detection equipment based on laser scanning

Abstract

The invention discloses steel wire rope wear degree defect detection equipment based on laser scanning, and belongs to the technical field of steel wire rope detection. Comprising a frame body connecting assembly, one end of the frame body connecting assembly is connected with a cleaning assembly, the end, close to the cleaning assembly, of an inner cavity of the frame body connecting assembly is connected with a fixed correction assembly, and the end, facing the middle of the frame body connecting assembly, of the fixed correction assembly is connected with a first detection assembly; the detection mechanisms in the first detection assembly and the second detection assembly are distributed in a staggered mode, the multiple detection mechanisms jointly form an annular detector, full-perimeter dead-corner-free covering of the steel wire rope can be achieved, the staggered design can fill up the detection gap of a single detection assembly, and tiny defects of gaps between steel wire rope strands and other areas are effectively captured; contact detection can quickly respond to obvious defects such as tilting and wire breaking of the surface of the steel wire rope, and the infrared sensor monitors the activity threshold value of the detection block in real time, so that the defects are quickly judged.

Description

Technical Field

[0001] This invention relates to the field of wire rope testing technology, and more specifically, to a laser scanning-based device for detecting wear defects in wire ropes. Background Technology

[0002] As a high-strength flexible load-bearing component, steel wire rope is widely used in various industrial fields such as mine hoisting, construction lifting, elevator operation, port loading and unloading, and cableway transportation due to its advantages such as high tensile strength, good toughness, and strong load-bearing capacity. The safety of its operation is directly related to the safety of personnel, normal operation of equipment, and continuity of production. Therefore, accurate and efficient detection of defects such as wear, broken wires, and corrosion of steel wire rope is a key link to ensure the safe and stable operation of various industrial scenarios.

[0003] Existing wire rope wear defect detection technologies are mainly divided into two categories: manual inspection and automated inspection. Manual inspection is a traditional method that relies on inspectors to judge the defects of wire ropes by visual observation, caliper measurement, and touch. This method is greatly affected by human factors such as the inspector's experience, sense of responsibility, and visual fatigue. It is not only inefficient and inaccurate, but also unable to quantitatively assess the degree of wear and the number of broken wires. Furthermore, it is prone to missed detections and misjudgments for hidden dangers that are difficult to identify with the naked eye, such as gaps between wire rope strands, minor surface wear, and internal defects. Summary of the Invention

[0004] The purpose of this invention is to provide a laser scanning-based device for detecting wear defects in wire ropes, in order to solve the problems mentioned in the background art.

[0005] A laser scanning-based wire rope wear defect detection device includes a frame connection assembly. One end of the frame connection assembly is connected to a cleaning assembly, and the end of the inner cavity of the frame connection assembly near the cleaning assembly is connected to a fixing and straightening assembly. The end of the fixing and straightening assembly facing the middle part of the frame connection assembly is connected to a first detection assembly, and the end of the first detection assembly away from the fixing and straightening assembly is equipped with a second detection assembly. The first detection component includes a detection frame, the inner surface of which has a first groove, and a plurality of detection mechanisms are connected in the inner cavity of the first groove. The outer sides of the detection frame are connected to second rectangular connecting blocks, the upper surface of each second rectangular connecting block has a first circular hole, and an infrared sensor is connected in the inner cavity of the first groove on the inner surface of the detection frame. The first circular hole fits into a circular support rod.

[0006] Preferably, the detection mechanism includes a detection block, and a first circular guide rod is connected to one end surface of the detection block away from the center of the detection frame. A first reset spring is sleeved on the outer side of the first circular guide rod, and the two sides of the detection block facing the center of the detection frame are arc-shaped.

[0007] Preferably, a plurality of the detection mechanisms together form a ring detector, the components of the second detection component are the same as those of the first detection component, and the detection mechanisms in the first detection component and the detection mechanisms in the second detection component are misaligned.

[0008] Preferably, the centers of the frame connecting assembly, cleaning assembly, fixing and correcting assembly, first detection assembly and second detection assembly are all on the same horizontal plane, and the intervals between the plurality of laser scanners are all sixty degrees.

[0009] Preferably, the frame connecting assembly includes a base, the upper end of the base is connected to a connecting frame, the rear end surface of the connecting frame is connected to a plurality of laser scanners, and the lower end inner cavity of the connecting frame is connected to a plurality of circular support rods on both sides, with a limit block connected to the upper end surface of each circular support rod.

[0010] Preferably, each of the circular support rods is connected to a cap at its top, and the connecting frame is connected to semi-circular connecting blocks on the upper and lower sides of the end near the cleaning component. Each semi-circular connecting block has a connecting groove on the circular end surface facing the connecting frame. The connecting frame is composed of two semi-circular frames, which are rotatably connected by a rotating rod.

[0011] Preferably, the cleaning assembly includes a cleaning frame, a first annular connecting block connected to the inner cavity of the cleaning frame, a cleaning brush connected to the inner cavity of the first annular connecting block, an external toothed ring connected to the outer surface of the first annular connecting block, a first gear meshing with the outer surface of the external toothed ring, a first drive motor connected to the shaft of the first gear, a connecting block connected to one end of the cleaning frame facing the fixing and correcting assembly, and grooves provided at the lower ends of both the first annular connecting block and the cleaning frame, and the connecting block is composed of a second annular connecting block and rectangular connecting blocks connected to both ends of the second annular connecting block.

[0012] Preferably, the fixed correction component includes a fixed frame, a second groove is provided in the inner cavity of the fixed frame, and arc-shaped correction blocks are connected to the four positions of the second groove. A second circular guide rod is connected to one end surface of each arc-shaped correction block away from the center of the fixed frame. A second reset spring is sleeved on the outer surface of each second circular guide rod. Third rectangular connecting blocks are connected to the outer surfaces of both ends of the fixed frame. A second circular hole is provided on the upper surface of each third rectangular connecting block. The second circular hole fits with the circular support rod. The arc-shaped correction blocks are arc-shaped on both sides of the end facing the center of the fixed frame.

[0013] Compared with the prior art, the advantages of this invention are: In this invention, a three-level detection mechanism consisting of staggered two-stage contact detection and laser scanning final inspection is employed to achieve comprehensive and high-precision detection of wire rope defects. The detection mechanisms in the first and second detection components are staggered, and several detection mechanisms together form a ring detector, which can achieve full circumference coverage of the wire rope without blind spots. The staggered design can fill the detection gaps of a single detection component and effectively capture minute defects in areas such as the gaps between wire rope strands. Contact detection can quickly respond to obvious defects such as warping and broken wires on the surface of the wire rope. Infrared sensors monitor the activity threshold of the detection block in real time to achieve rapid defect determination. Subsequently, laser scanners are distributed in a ring at 60-degree intervals, and non-contact scanning is used to quantitatively evaluate parameters such as the wear depth and diameter change of the wire rope. The three-level detection works in synergy to ensure detection efficiency and significantly improve the accuracy of defect identification, avoiding missed detections and misjudgments. At the same time, the detection block adopts an arc-shaped design to prevent secondary damage to the surface of the wire rope.

[0014] 2. In this invention, the cleaning component uses a first drive motor to rotate the cleaning brush 360 degrees, which can thoroughly clean the surface of the wire rope of dust, oil, rust debris and other solid waste impurities, preventing impurities from blocking the laser signal or interfering with the contact of the detection mechanism. At the same time, the solid waste is discharged in time through the trough to prevent accumulation from affecting the detection. The fixing and correction component uses the cooperation of four arc-shaped correction blocks and a second reset spring to achieve adaptive clamping of wire ropes of different diameters. It can automatically correct the deviation, swaying and other bad postures of the wire rope, ensuring that the wire rope always moves smoothly along the axis of the equipment, ensuring the detection accuracy of the subsequent detection components and laser scanner, and reducing detection errors from the source.

[0015] 3. In this invention, the modular and detachable structural design optimizes the assembly and maintenance process of the equipment, improves equipment adaptability, and reduces operation and maintenance costs and operational difficulty. The frame connection component uses a structure of two semi-circular frames rotating together, facilitating wire rope installation and overall equipment maintenance. The first detection component, second detection component, and fixing and correction component can be quickly assembled and fixed through the cooperation of rectangular connecting blocks and circular support rods. The design of the limit block and cap ensures accurate component installation and positioning, and component calibration and replacement can be completed without disassembling the entire machine. The cleaning component achieves quick assembly and disassembly through the groove cooperation of the connecting block and the semi-circular connecting block, allowing for online maintenance of vulnerable parts and significantly shortening the maintenance cycle. Simultaneously, the adaptive structure of each component can adapt to wire ropes of different diameters, eliminating the need for manual clamp replacement and enabling rapid switching and testing of multiple specifications of wire ropes, improving testing efficiency and reducing manual operation intensity. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a side view of the present invention; Figure 3 This is a schematic diagram of the internal structure of the present invention; Figure 4 This is a schematic diagram of the frame connection component structure of the present invention; Figure 5 This is a schematic diagram of the cleaning component structure of the present invention; Figure 6 This is a rear view schematic diagram of the cleaning component of the present invention; Figure 7 This is a schematic diagram of the structure of the first detection component of the present invention; Figure 8 This is a schematic diagram of the detection mechanism structure of the present invention; Figure 9 This is a schematic diagram of the fixed correction component structure of the present invention.

[0017] Explanation of the numbered components in the diagram: 1. Frame connecting assembly; 101. Base; 102. Connecting frame; 103. Laser scanner; 104. Circular support rod; 105. Limiting block; 106. Cap; 107. Semi-circular connecting block; 108. Connecting groove; 2. Cleaning assembly; 201. Cleaning frame; 202. First annular connecting block; 203. Cleaning brush; 204. External gear ring; 205. First gear; 206. First drive motor; 207. Connecting block; 208. 1. Leakage groove; 3. Fixed correction component; 301. Fixed frame; 302. Second groove; 303. Arc-shaped correction block; 304. Second circular guide rod; 305. Second reset spring; 4. First detection component; 401. Detection frame; 402. First groove; 403. Detection mechanism; 404. Detection block; 405. First circular guide rod; 406. First reset spring; 407. Second rectangular connecting block; 408. First circular hole; 5. Second detection component. Detailed Implementation

[0018] Example: Please refer to Figure 1 , Figure 2 and Figure 3 A laser scanning-based wire rope wear defect detection device includes a frame connecting assembly 1, a cleaning assembly 2 connected to one end of the frame connecting assembly 1, a fixing and straightening assembly 3 connected to the end of the inner cavity of the frame connecting assembly 1 near the cleaning assembly 2, a first detection assembly 4 connected to the end of the fixing and straightening assembly 3 facing the middle part of the frame connecting assembly 1, and a second detection assembly 5 installed at the end of the first detection assembly 4 away from the fixing and straightening assembly 3. Please see Figure 7 The first detection component 4 includes a detection frame 401. A first groove 402 is provided on the inner surface of the detection frame 401. A plurality of detection mechanisms 403 are connected in the inner cavity of the first groove 402. A second rectangular connecting block 407 is connected to both sides of the outer side of the detection frame 401. A first circular hole 408 is provided on the upper surface of each second rectangular connecting block 407. An infrared sensor is connected in the inner cavity of the first groove 402 on the inner surface of the detection frame 401. The first circular hole 408 fits into the circular support rod 104.

[0019] Please see Figure 8 The detection mechanism 403 includes a detection block 404. A first circular guide rod 405 is connected to one end surface of the detection block 404 away from the center of the detection frame 401. A first reset spring 406 is sleeved on the outside of the first circular guide rod 405. The two sides of the detection block 404 facing the center of the detection frame 401 are arc-shaped.

[0020] Please see Figure 7 and Figure 3Several detection mechanisms 403 together form a ring detector. The components of the second detection component 5 are the same as those of the first detection component 4. The detection mechanisms 403 in the first detection component 4 and the detection mechanisms 403 in the second detection component 5 are misaligned.

[0021] Please see Figure 3 The centers of the frame connecting component 1, cleaning component 2, fixing and correction component 3, first detection component 4 and second detection component 5 are all on the same horizontal plane, and the intervals of several laser scanners 103 are all sixty degrees.

[0022] Please see Figure 4 The frame connecting assembly 1 includes a base 101, a connecting frame 102 connected to the upper end of the base 101, a plurality of laser scanners 103 connected to the rear end surface of the connecting frame 102, and a plurality of circular support rods 104 connected to both sides of the lower end inner cavity of the connecting frame 102, with a limit block 105 connected to the upper end surface of each circular support rod 104.

[0023] Please see Figure 4 Each circular support rod 104 has a cap 106 connected to its top end, and the connecting frame 102 has semi-circular connecting blocks 107 connected to the upper and lower sides of the end near the cleaning component 2. Each semi-circular connecting block 107 has a connecting groove 108 on the circular end surface facing the connecting frame 102. The connecting frame 102 is composed of two semi-circular frames, and the two semi-circular frames are rotatably connected by a rotating rod.

[0024] Specifically, the modular and detachable structural design optimizes the equipment's assembly and maintenance processes, improves equipment adaptability, and reduces operation and maintenance costs and operational difficulty. The frame connection component 1 uses a structure where two semi-circular frames rotate and connect, facilitating wire rope installation and overall equipment maintenance. The first detection component 4, the second detection component 5, and the fixing and correction component 3 can be quickly assembled and fixed through the cooperation of rectangular connecting blocks and circular support rods 104. The design of the limit block 105 and the cap 106 ensures accurate component installation and positioning, and component calibration and replacement can be completed without disassembling the entire machine. The cleaning component achieves quick assembly and disassembly through the groove cooperation between the connecting block 207 and the semi-circular connecting block 107, allowing for online maintenance of vulnerable parts and significantly shortening the maintenance cycle. Simultaneously, the adaptive structure of each component can adapt to wire ropes of different diameters, eliminating the need for manual clamp replacement and enabling rapid switching and testing of multiple wire rope specifications, improving testing efficiency and reducing manual labor intensity.

[0025] Please see Figure 5 and Figure 6The cleaning component 2 includes a cleaning frame 201. A first annular connecting block 202 is connected to the inner cavity of the cleaning frame 201. A cleaning brush 203 is connected to the inner cavity of the first annular connecting block 202. An external toothed ring 204 is connected to the outer surface of the first annular connecting block 202. A first gear 205 meshes with the outer surface of the external toothed ring 204. A first drive motor 206 is connected to the shaft of the first gear 205. A connecting block 207 is connected to one end of the cleaning frame 201 facing the fixed correction component 3. A groove 208 is opened at the lower end of both the first annular connecting block 202 and the cleaning frame 201. The connecting block 207 is composed of a second annular connecting block and rectangular connecting blocks connected to both ends of the second annular connecting block.

[0026] Specifically, the cleaning component 2 drives the cleaning brush 203 to rotate 360° via the first drive motor 206, which can thoroughly clean the surface of the wire rope of dust, oil, rust debris and other solid waste impurities, preventing impurities from blocking the laser signal or interfering with the contact of the detection mechanism 403. At the same time, the solid waste is discharged in time through the trough 208 to prevent accumulation from affecting the detection. The fixing and correction component 3 uses the cooperation of the arc-shaped correction blocks 303 in four directions and the second reset spring 305 to achieve adaptive clamping of wire ropes of different diameters. It can automatically correct the deviation, swaying and other bad postures of the wire rope, ensuring that the wire rope always moves smoothly along the axis of the equipment, ensuring the detection accuracy of the subsequent detection components and laser scanner 103, and reducing detection errors from the source.

[0027] Please see Figure 9 The fixed correction component 3 includes a fixed frame 301. A second groove 302 is provided in the inner cavity of the fixed frame 301. Arc-shaped correction blocks 303 are connected to the four positions of the second groove 302. A second circular guide rod 304 is connected to one end surface of each arc-shaped correction block 303 away from the center of the fixed frame 301. A second reset spring 305 is sleeved on the outer surface of each second circular guide rod 304. A third rectangular connecting block is connected to the outer surfaces of both ends of the fixed frame 301. A second circular hole is provided on the upper surface of each third rectangular connecting block. The second circular hole fits with the circular support rod 104. The arc-shaped correction blocks 303 are arc-shaped on both sides at the end facing the center of the fixed frame 301.

[0028] Specifically, a three-level detection mechanism consisting of staggered two-stage contact detection and laser scanning final inspection is used to achieve comprehensive and high-precision detection of wire rope defects. The detection mechanisms 403 in the first detection component 4 and the second detection component 5 are staggered, and several detection mechanisms 403 together form a ring detector, which can achieve full coverage of the wire rope without dead angles. The staggered design can fill the detection gaps of a single detection component and effectively capture small defects in areas such as the gaps between wire rope strands. Contact detection can quickly respond to obvious defects such as warping and broken wires on the surface of the wire rope. Infrared sensors monitor the activity threshold of the detection block 404 in real time to achieve rapid defect judgment. Subsequently, the laser scanners 103 are distributed in a ring at sixty-degree intervals. Through non-contact scanning, parameters such as the wear depth and diameter change of the wire rope are quantitatively evaluated. The three-level detection works together to ensure detection efficiency and greatly improve the accuracy of defect identification, avoiding missed detections and misjudgments. At the same time, the detection block 404 adopts an arc-shaped design to prevent secondary damage to the surface of the wire rope.

[0029] Working principle: First, the second rectangular connecting block 407 connected at both ends of the two detection components is moved downward along the circular support rod 104 until the second rectangular connecting block 407 contacts the upper surface of the limiting block 105. At this time, the two detection components are fixed by the cap 106. Then, the same operation is performed to fix the fixing and correction component 3. Then, the connecting groove 108 opened at the center of the connecting frame 102 of the half-arc connecting block 107 connected to the lower end of the circular frame is aligned with the connecting block 207 in the cleaning component 2. Finally, the half-circular frames at the upper and lower ends of the circular frame are fixed by nuts, thereby fixing the cleaning component 2. Once the two detection components, the fixing and correction component 3, and the cleaning component 2 are all fixed, the first drive motor 206 will be started, driving the first gear 205 to rotate, thereby driving the outer gear ring 204 to rotate, and then driving the first annular connecting block 202 to rotate. As the first annular connecting block 202 rotates, the cleaning brush 203 connected to the inner surface of the first annular connecting block 202 will rotate around the center. At this time, the steel wire rope to be tested will be moved along the center of the cleaning frame 201 toward the center of the other end of the connecting frame 102. The steel wire rope will move into the inner cavity of the cleaning frame 201, and the cleaning brush 203 will perform a 360-degree cleaning operation on the steel wire rope without dead angles. The solid waste generated by the steel wire rope during the cleaning process will fall to the outside as the slot 208 opened on the surface of the first annular connecting block 202 coincides with the slot 208 opened at the lower end of the cleaning frame 201. As the wire rope moves forward after the cleaning operation, if the wire rope moves into the inner cavity of the fixed frame 301, it will exert pressure on the arc-shaped correction block 303, causing the arc-shaped correction blocks 303 connected in four directions of the fixed frame 301 to move along the second circular guide rod 304 toward the end away from the center of the fixed frame 301, until the arc-shaped correction blocks 303 in all four directions are in contact with the outer surface of the wire rope. At this time, the wire rope is corrected, and the corrected wire rope will continue to move toward one end of the laser scanner 103. When the wire rope moves into the inner cavity of the detection frame 401 in the first detection component 4, it will exert pressure on the detection blocks 404 in several detection mechanisms 403, thereby causing the detection blocks 404 in several detection mechanisms 403 to move along the first circular guide rod 405 toward the end away from the center of the detection frame 401 until all the detection blocks 404 contact the outer surface of the wire rope. At this time, if a wire on the surface of the wire rope breaks and sticks up, if the sticking wire passes through the first detection component 4, the detection block 404 in contact with the sticking wire will continue to move along the first circular guide rod 405 toward the end away from the center of the detection frame 401. At this time, if the infrared sensor detects that a small number of detection blocks 404 exceed the activity threshold of other detection blocks 404, it will stop the wire rope detection operation and indicate that the wire rope does not meet the detection standard. If the wire rope passes through the detection operation of the first detection component 4, the second detection component 5 will perform a second detection operation on the wire rope to avoid missed detection on the surface of the wire rope, thereby improving the accuracy of the wire rope detection. After the two detection operations, the wire rope will continue to move towards the center of the end of the connecting frame 102 facing the laser scanner 103. When the wire rope moves out of the connecting frame 102, several laser scanners 103 will perform laser scanning operations on the wire rope and perform a third detection operation on the wire rope to check whether the wire rope meets the detection standards, until the wire rope detection is completed, and all operations end.

[0030] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A laser scanning-based wire rope wear defect detection device, comprising a frame connecting assembly (1), characterized in that: One end of the frame connecting assembly (1) is connected to a cleaning assembly (2), and the end of the inner cavity of the frame connecting assembly (1) near the cleaning assembly (2) is connected to a fixing and correcting assembly (3). The end of the fixing and correcting assembly (3) facing the middle part of the frame connecting assembly (1) is connected to a first detection assembly (4), and the end of the first detection assembly (4) away from the fixing and correcting assembly (3) is equipped with a second detection assembly (5). The first detection component (4) includes a detection frame (401), the inner surface of the detection frame (401) is provided with a first groove (402), a plurality of detection mechanisms (403) are connected in the inner cavity of the first groove (402), and a second rectangular connecting block (407) is connected to both sides of the outer side of the detection frame (401), and a first circular hole (408) is provided on the upper surface of each second rectangular connecting block (407). The frame connecting assembly (1) includes a base (101), the upper end of which is connected to a connecting frame (102), the rear end surface of which is connected to a plurality of laser scanners (103), and the lower end inner cavity of the connecting frame (102) is connected to a plurality of circular support rods (104), the upper end surface of each circular support rod (104) is connected to a limit block (105).

2. The laser scanning-based wire rope wear defect detection device according to claim 1, characterized in that: The detection mechanism (403) includes a detection block (404), and a first circular guide rod (405) is connected to one end surface of the detection block (404) away from the center of the detection frame (401). A first reset spring (406) is sleeved on the outer side of the first circular guide rod (405).

3. The laser scanning-based wire rope wear defect detection device according to claim 2, characterized in that: Several of the aforementioned detection mechanisms (403) together form a ring detector. The components of the second detection component (5) are the same as those of the first detection component (4). The detection mechanism (403) in the first detection component (4) and the detection mechanism (403) in the second detection component (5) are misaligned.

4. The laser scanning-based wire rope wear defect detection device according to claim 3, characterized in that: The centers of the frame connecting component (1), cleaning component (2), fixing and correcting component (3), first detection component (4) and second detection component (5) are all on the same horizontal plane, and the intervals between the laser scanners (103) are all sixty degrees.

5. The laser scanning-based wire rope wear defect detection device according to claim 4, characterized in that: Each of the circular support rods (104) has a cap (106) connected to its top end, and the connecting frame (102) has semi-circular connecting blocks (107) connected to the upper and lower sides of the end near the cleaning component (2). Each semi-circular connecting block (107) has a connecting groove (108) on its circular end surface facing the connecting frame (102).

6. The laser scanning-based wire rope wear defect detection device according to claim 5, characterized in that: The cleaning component (2) includes a cleaning frame (201), a first annular connecting block (202) is connected to the inner cavity of the cleaning frame (201), a cleaning brush (203) is connected to the inner cavity of the first annular connecting block (202), and an external gear ring (204) is connected to the outer surface of the first annular connecting block (202). A first gear (205) meshes with the outer surface of the external gear ring (204), and a first drive motor (206) is connected to the shaft of the first gear (205). A connecting block (207) is connected to one end of the cleaning frame (201) facing the fixed correction component (3), and a slot (208) is provided at the lower end of both the first annular connecting block (202) and the cleaning frame (201).

7. The laser scanning-based wire rope wear defect detection device according to claim 6, characterized in that: The fixed correction component (3) includes a fixed frame (301), and a second groove (302) is provided in the inner cavity of the fixed frame (301). Arc-shaped correction blocks (303) are connected to the four positions of the second groove (302). A second circular guide rod (304) is connected to one end surface of each arc-shaped correction block (303) away from the center of the fixed frame (301). A second reset spring (305) is sleeved on the outer surface of each second circular guide rod (304).

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