Multi-physics field integrated steel wire rope defect detection device

Abstract

The invention relates to a multi-physics field integrated steel wire rope defect detection device which comprises a plurality of detection units, a driving part and a transmission assembly, and further comprises a fixed seat and a movable seat which is mounted on the fixed seat and can rotate around the channel, a plurality of magnetic sensors are arranged on the movable seat, and the plurality of magnetic sensors are arranged around the channel at intervals in the circumferential direction; and when the steel wire rope passes through the channel, the driving piece drives the movable seat to rotate through the transmission assembly, so that each magnetic sensor obtains a magnetic field signal on a spiral path on the surface of the steel wire rope to be detected. According to the invention, more comprehensive and more efficient quantitative detection of steel wire rope defects is realized.

Description

Technical Field

[0001] This invention belongs to the field of non-destructive testing technology for steel wire ropes, specifically relating to a multi-physics integrated steel wire rope defect detection device. Background Technology

[0002] Steel wire ropes are commonly used in industrial production, tourism, coal mining, shipbuilding, and daily lifting and hoisting operations as traction, load-bearing, and connecting components. Prolonged use under heavy loads can easily lead to wire breakage, loosening, and wear damage. Use in harsh environments can cause corrosion and shrinkage, reducing load-bearing capacity and posing a significant safety hazard, endangering personal and equipment safety. Therefore, real-time monitoring and prediction of steel wire rope damage, along with rapid, non-destructive, automated inspection technology, has significant social and economic benefits.

[0003] Common methods for detecting damage in wire ropes include magnetic flux leakage (MFL) testing and eddy current testing. MFL testing is a non-destructive testing technique for ferromagnetic materials. It involves magnetizing the object under test until it becomes saturated. When defects exist in the material, magnetic field lines "leak" from the defects into the surrounding space. The leakage magnetic field signal is captured by a sensor to identify the defects, and it can detect defects with a depth ≤20mm. Eddy current testing utilizes an alternating magnetic field to induce eddy currents on the surface of conductive materials. Eddy current sensors collect eddy current magnetic field signals, and the changes in the eddy current magnetic field are analyzed to detect defects on the surface and near the surface (≤5mm) of the wire rope under test, such as cracks, corrosion, and holes.

[0004] Defect acquisition devices are devices used in non-destructive testing equipment to collect various defect signals. Traditional defect information acquisition devices have two main problems: firstly, they cannot completely acquire leakage magnetic signals in the circumferential direction, resulting in missing defect signals; secondly, they are difficult to achieve integrated acquisition of multiple defect signals. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a multi-physics field integrated wire rope defect detection device. This device aims to solve the problem of incomplete acquisition of leakage magnetic field signals in the circumferential direction of the wire rope, and can simultaneously integrate the acquisition of leakage magnetic field and eddy current field signals, thereby realizing a more comprehensive and efficient quantitative detection of wire rope defects.

[0006] The technical solution of this invention is to provide a multi-physics integrated wire rope defect detection device, comprising several detection units, a driving component, and a transmission assembly. Each detection unit has a channel for the wire rope to be tested to pass through, and further includes a fixed base and a movable base mounted on the fixed base that can rotate around the channel. The movable base is provided with multiple magnetic sensors, which are spaced apart around the channel circumferentially. When the wire rope passes through the channel, the driving component drives the movable base to rotate through the transmission assembly, so that each magnetic sensor obtains the magnetic field signal on the spiral path on the surface of the wire rope to be tested.

[0007] As the steel wire rope under test continuously passes by, the magnetic sensor can rotate around the steel wire rope. Therefore, a single magnetic sensor obtains the magnetic field signal on the spiral path of the steel wire rope surface, and the spiral path fitting of multiple magnetic sensors better covers the magnetic field signal on the surface of the steel wire rope.

[0008] This application not only solves the problem of holographic acquisition of leakage magnetic signals, but also solves the problem of integrated acquisition of multi-physics fields. Through ingenious structural design, it realizes the integrated acquisition of eddy current field signals and magnetic field signals.

[0009] Preferably, the mounting base is provided with a plurality of eddy current sensors, which are arranged at intervals around the channel in the circumferential direction.

[0010] Preferably, the eddy current sensor and the magnetic sensor are located at different positions in the axial direction.

[0011] Preferably, at least two of the detection units are arranged coaxially at intervals, and the movable seats of all detection units rotate synchronously when the wire rope passes through the channel.

[0012] Preferably, in different detection units, the magnetic sensors on their movable seats are staggered in the circumferential direction.

[0013] Preferably, the movable seat is a ring structure with the channel at its center.

[0014] Preferably, the movable seat is provided with a gear ring that meshes with the gear.

[0015] Preferably, the driving component includes a first driving component and a second driving component. The first driving component actively provides driving force; the second driving component is driven by the wire rope during detection, passively providing driving force, and a clutch device is provided between it and the transmission assembly. The clutch device can adopt existing technology such as the generator clutch disclosed in Chinese Patent Publication No. CN 113287856 A, and its transmission gear is replaced with a transmission pulley.

[0016] Preferably, a transmission belt and a bevel gear transmission assembly are also provided between the clutch device and the transmission assembly.

[0017] Preferably, the transmission assembly includes a rotating shaft, a drive gear, and the gear ring; the rotating shaft is arranged parallel to the axis of the channel and is driven by the drive member; the drive gear is fixedly fixed to the rotating shaft at axial intervals and meshes with the gear ring on the corresponding movable seat.

[0018] Preferably, the first driving component is a motor, and the second driving component is a guide wheel that presses against the steel wire rope to be tested.

[0019] Furthermore, it also includes a shield, with all detection units placed inside the shield and the drive unit placed outside the shield.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] (1) As the steel wire rope under test continues to pass through, the magnetic sensor can rotate around the steel wire rope under test. Therefore, a single magnetic sensor obtains the magnetic field signal on the spiral path on the surface of the steel wire rope under test, and the spiral path fitting of multiple magnetic sensors better covers the magnetic field signal on the surface of the steel wire rope.

[0022] (2) The multi-level detection units are arranged at intervals along the axial direction, and the magnetic sensors of different detection units are staggered, which can obtain enough magnetic field signals on different spiral paths. After fitting, the holographic magnetic field signal on the surface of the wire rope can be basically obtained.

[0023] (3) Multi-physics field integrated detection improves detection efficiency and presents defect information in multiple dimensions. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the split structure of the detection device of the present invention;

[0025] Figure 2 A schematic diagram of the split structure of a single detection unit;

[0026] Figure 3 and Figure 4 for Figure 1 The diagram shows the assembled detection device at different angles (shielding cover omitted);

[0027] Figure 5 for Figure 4 A cross-sectional view along the axis of rotation at the angle shown;

[0028] Figure 6 for Figure 5 A magnified view of part A shown;

[0029] Figure 7 A schematic diagram of the spiral path of the magnetic field signal collected by the magnetic sensor.

[0030] In the picture:

[0031] 1. Detection unit; 11. Mounting base; 12. Eddy current sensor; 13. Mounting lug; 14. Insulating inner cover; 15. Movable seat bearing; 16. Movable seat; 17. Magnetic sensor.

[0032] 2. Transmission components; 21. Gear ring; 22. Drive gear; 23. Rotating shaft; 24. Gear ring fixing block; 25. Fastening bolts;

[0033] 3. Mounting bracket; 31. Front fixing plate; 32. Fixing post; 33. Reinforcing plate; 34. Rear fixing plate;

[0034] 4. Shielding cover;

[0035] 5. First driving component;

[0036] 6. Guide wheel;

[0037] 7. Clutch mechanism;

[0038] 8. Passageway;

[0039] 9. Drive belt

[0040] 10. Bevel gear transmission assembly; 101. Integrated bevel pulley; 102. Transmission bevel gear. Detailed Implementation

[0041] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0042] like Figures 1-3 As shown, a wire rope defect detection device includes a detection unit 1, a driving component, and a transmission assembly 2. The detection unit includes several units spaced apart along the axial direction. The detection unit 1 has a channel 8 for the wire rope to be tested to pass through. The detection unit 1 includes a fixed base 11 and a movable base 16 mounted on the fixed base 11 and capable of rotating around the channel 8. The movable base 16 is provided with multiple magnetic sensors 17, which are spaced apart around the channel in the circumferential direction to form a magnetic sensor array. When the wire rope passes through the channel 8, the driving component drives the movable base 16 to rotate through the transmission assembly 2, so that each magnetic sensor in the magnetic sensor array obtains the magnetic field signal on the spiral path on the surface of the wire rope to be tested.

[0043] This embodiment includes at least two detection units 1, which are coaxially spaced apart. When the wire rope passes through the channel 8, the movable seats of all detection units rotate synchronously. In different detection units, the magnetic sensors 17 on their movable seats are staggered in the circumferential direction. The magnetic sensor array of each detection unit contains n magnetic sensors. Each detection unit can obtain magnetic field signals on n spiral paths on the surface of the wire rope under test. The magnetic sensors of different detection units are staggered, so the spiral path magnetic field signals obtained by different detection units are also staggered. With m detection units, m×n spiral path magnetic field signals staggered in the circumferential direction can be obtained when they rotate synchronously. Figure 7 ).by Figure 1 Taking the implementation method shown as an example, which includes a three-level detection unit and a magnetic sensor array of 20 magnetic sensors in each detection unit, the three-level detection units rotate synchronously and obtain a total of 60 magnetic field signals of spiral paths staggered in the circumferential direction. The holographic magnetic signal of the surface of the steel wire rope under test can be obtained by signal fitting.

[0044] This invention not only solves the problem of holographic acquisition of leakage magnetic signals, but also addresses the problem of integrated acquisition of multi-physics fields. Through ingenious structural design, it achieves integrated acquisition of eddy current field signals and magnetic field signals. In this embodiment, multiple eddy current sensors 12 are installed on the fixed base 11. These multiple eddy current sensors are arranged at intervals around the channel 5 in the circumferential direction to form an eddy current sensor array, which is used to synchronously acquire eddy current signals on the surface of the steel wire rope under test.

[0045] As one implementation method, an exploded view of part of the structure of the detection unit and the transmission assembly is shown below. Figure 2 As shown, the device includes a fixed base 11, an eddy current sensor array, a movable base 16, and a magnetic sensor array. The fixed base 11 is an annular base with a channel 8 at its center for the steel wire rope to be tested to pass through. Several radial through holes are evenly distributed along the circumference of the annular base, and several eddy current sensors 12 are installed in the through holes to form a magnetic sensor array. An insulating inner cover 14 is provided on the inner ring surface of the annular fixed base. The eddy current sensor array is separated from the channel by the insulating inner cover 14. Detection holes are opened on the insulating inner cover at positions corresponding to the eddy current sensors, allowing the eddy current sensors to collect the eddy current field signal on the surface of the steel wire rope to be tested.

[0046] See Figure 2 and Figure 6 The movable seat 16 is an annular structure with a channel 8 at its center. Several mounting holes are evenly distributed on the outer circumference of the annular structure. Several magnetic sensors 17 are installed in the mounting holes to form a magnetic sensor array. The magnetic sensor array can be a high-sensitivity Hall element array. One axial end of the movable seat 16 is rotatably mounted on the fixed seat 11 through the movable seat bearing 15. The movable seat 16 and the fixed seat 11 are located at different positions in the axial direction.

[0047] As one implementation method, see Figure 1 The transmission component 2 adopts gear transmission, including a gear ring 21, a drive gear 22, and a rotating shaft 23. The gear ring 21 is fixed to the other end face of the movable seat 16 along the axial direction (the gear ring and the bearing are located at opposite ends of the movable seat along the axial direction). The gear ring 21 can be fixed to the movable seat 16 by a gear ring fixing block 24 and a fastening bolt 25. Both the gear ring and the gear ring fixing block have a channel for the steel wire rope to be tested to pass through. The gear ring fixing block can be multiple blocks along the circumference, and the central hole formed by the multiple gear ring fixing blocks is the channel for the steel wire rope to pass through. The drive gear 22 is fixed on the rotating shaft 23, and the gear ring and the gear mesh with each other. The rotating shaft 23 is installed parallel to the axis of the channel 8. When the rotating shaft 23 is driven by the drive component, it drives the movable seat 16 to rotate around the channel 8 through gear transmission.

[0048] Several detection units 1 are distributed at intervals along the axial direction and installed on corresponding fixed frames. In this embodiment, see [reference needed]. Figure 1 , Figure 3 and Figure 5 The fixing frame 3 includes a front fixing plate 31 (the fixing plate through which the wire rope passes during testing), fixing posts 32, and a rear fixing plate 34. Both the front and rear fixing plates are square plates with a through hole 8 in the center for the wire rope to pass through. The two ends of the four fixing posts 32 are fixed to the four corners of the front and rear fixing plates, respectively. Both ends of the rotating shaft 23 are rotatably mounted on the front and rear fixing plates via corresponding bearings. In some embodiments, the rotating shaft 23 is located at the center of two fixing posts on the same side. The fixing seat 11 of the testing unit is fixedly connected to the corresponding fixing post 32 via four fixing ears 13. In other embodiments, the fixing ears 13 have axial through holes, pass through the corresponding fixing post 32, and are locked in place by bolts. The drive gear 22 is fixedly fitted onto the corresponding position of the rotating shaft 23. The movable seat 16 of the testing unit is meshed with the drive gear via a gear ring 21. To enhance the strength of the mounting bracket, a reinforcing plate 33 can be installed between the front and rear mounting plates. The two ends of the reinforcing plate 33 are fixed to the outer edges of the front and rear mounting plates respectively. The reinforcing plate 33 can be designed to be lightweight while ensuring the reinforcement effect.

[0049] After all the detection units and the mounting brackets are assembled, they are encapsulated in the shielding cover 4. The two ends of the shielding cover 4 are sealed and fixed to the front and rear mounting plates respectively. The shielding cover 4 is a multi-layer magnetic shielding cover. In order to eliminate the influence of the motor on the magnetic field, the motor of the first drive unit 5 is also placed in the corresponding magnetic shielding cover.

[0050] The rotating shaft 23 is driven by a driving component, which may include a first driving component 5 and a second driving component. The first driving component is an active driving component, and the second driving component is a passive driving component.

[0051] The first driving component and the second driving component are located at the two ends of the axial direction of the rotating shaft 23, respectively. In this embodiment, the first driving component 5 is a motor, which is fixed on the outside of the rear fixing plate 34. The output shaft of the motor is coaxially and fixedly connected to the rotating shaft 23, and actively drives the rotating shaft 23 to rotate.

[0052] Limiting guide wheel assemblies 6 are respectively installed on the outer sides of the front and rear fixed plates. When the wire rope passes through, the limiting guide wheel assemblies 6 abut against the wire rope, and the wire rope drives the guide wheels to rotate. The second driving component is driven by one of the guide wheels on the front fixed plate 31. A clutch device 7 and a bevel gear transmission assembly 9 are installed between the guide wheel and the rotating shaft. When the wire rope is being tested, it drives the guide wheel to rotate. The rotation of the guide wheel drives the bevel gear transmission assembly 10 through the clutch device 7 and the transmission belt 9, which in turn drives the rotating shaft 23 to rotate, passively providing driving force.

[0053] The clutch mechanism draws inspiration from existing technologies such as the generator clutch disclosed in CN113287856A, replacing its transmission gear with a pulley. As one implementation method, see [link to relevant documentation]. Figures 3-6 The pulley (not shown in the figure) and the rotating shaft 23 are connected by a transmission belt 9 and a bevel gear transmission assembly 10. The bevel gear transmission assembly 10 includes an integrated bevel pulley 101 and transmission bevel teeth 102. The end of the rotating shaft 23 that extends out of the front fixed plate is fixedly connected to the transmission bevel teeth 102. The integrated bevel pulley 101 is mounted on the front fixed plate and close to the mounting point of the rotating shaft. The transmission bevel teeth of the integrated bevel pulley 101 cooperate with the transmission bevel teeth 102 at the end of the rotating shaft to form a bevel gear pair. The transmission belt is wound around the pulley and the integrated bevel pulley.

[0054] When the clutch is activated, the pulley and guide wheel are connected and fixed coaxially. When the wire rope passes through, it drives the guide wheel to rotate. The rotation of the guide wheel drives the pulley to rotate synchronously. The pulley drives the integrated bevel gear pulley 101 to rotate through the transmission belt 9. The bevel teeth of the integrated bevel gear pulley 101 drive the transmission bevel gear 102 to rotate, which in turn drives the rotating shaft 23 to rotate. The rotating shaft 23 drives the movable seat to rotate through the gear and gear ring, and the Hall sensor array rotates.

[0055] When the clutch is closed, the pulley and guide wheel disengage, and the pulley, drive belt, and bevel gear transmission assembly stop working.

[0056] The first driving component 5 is used first. Under normal circumstances, the pulley of the clutch device is disengaged from the guide wheel 6. When the first driving component is without power or malfunctions, the clutch device is operated to make the pulley of the clutch device and the guide wheel coaxially and fixedly connected, thus starting the passive drive.

[0057] The working principle of this invention is as follows:

[0058] The steel wire rope to be tested passes through the channel from left to right. Figure 1 and Figure 5(The direction indicated by the middle arrow is the direction the wire rope travels). The first driving component drives the rotating shaft to rotate, which in turn drives the movable seat of the detection unit to rotate via the gear assembly. The Hall array of the three-stage detection unit rotates synchronously, detecting the magnetic signals on different helical paths on the surface of the wire rope. The eddy current sensor array on the fixed seat collects the eddy current signals on the surface of the wire rope under test.

[0059] When the first drive component loses power or malfunctions, the clutch device can be activated to engage its pulley with the guide wheel, which then passively drives the shaft to rotate.

[0060] This invention can more comprehensively collect the leakage magnetic signal of the outer periphery of the steel wire rope under test.

[0061] The above description only illustrates preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. Any equivalent procedural modifications made using this specification are included within the patent protection scope of this invention.

Claims

1. A multi-physics integrated wire rope defect detection device, characterized in that: include The system includes several detection units, each having a detection channel through which the steel wire rope to be tested passes, and also includes a fixed base and a movable base mounted on the fixed base and capable of rotating around the channel. The movable base is provided with multiple magnetic sensors, which are spaced apart around the channel in a circumferential direction. The driving component and transmission assembly, when the wire rope passes through the channel, the driving component drives the movable seat to rotate through the transmission assembly, so that the plurality of magnetic sensors obtain the magnetic field signal on the spiral path on the surface of the wire rope to be tested.

2. The multi-physics integrated wire rope defect detection device according to claim 1, characterized in that: The mounting base is provided with a plurality of eddy current sensors, which are arranged at intervals around the channel in a circumferential direction.

3. The multi-physics integrated wire rope defect detection device according to claim 2, characterized in that: The eddy current sensor and the magnetic sensor are located at different positions in the axial direction.

4. The multi-physics integrated wire rope defect detection device according to claim 1, characterized in that: Several detection units are arranged coaxially at intervals, and the movable seats of all detection units rotate synchronously when the wire rope passes through the channel.

5. The multi-physics integrated wire rope defect detection device according to claim 4, characterized in that: In different detection units, the magnetic sensors on their movable seats are staggered in the circumferential direction.

6. The multiphysics integrated wire rope defect detection device according to claim 1, characterized in that: The movable seat is a ring structure with the channel at its center.

7. The multi-physics integrated wire rope defect detection device according to claim 6, characterized in that: The movable seat is equipped with a gear ring that meshes with the gear.

8. The multiphysics integrated wire rope defect detection device according to claim 1, characterized in that: The driving component includes a first driving component and a second driving component. The first driving component actively provides driving force; the second driving component is driven by the steel wire rope when it is detected, passively providing driving force, and a clutch device is provided between it and the transmission assembly.

9. The multiphysics integrated wire rope defect detection device according to claim 8, characterized in that: The first driving component is a motor, and the second driving component is a guide wheel that presses against the steel wire rope to be tested.

10. The multiphysics integrated wire rope defect detection device according to claim 1, characterized in that: It also includes a shield, with all detection units placed inside the shield and the drive unit placed outside the shield.

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