Online detection equipment for steel wire rope
By using a motion electromagnetic box, a non-contact weak magnetic sensing sensor, and a dynamically adjustable probe design in the wire rope inspection equipment, the problems of slow inspection speed and susceptibility to environmental interference in existing inspection methods have been solved, achieving efficient and accurate wire rope inspection and improving the safety and efficiency of the production line.
Patent Information
- Application Number
- CN202520063964.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-01-10
- Publication Date
- 2026-01-09
- Estimated Expiration
- 2035-01-10
AI Technical Summary
Existing wire rope testing methods suffer from problems such as slow testing speed, high cost, and susceptibility to environmental interference, making it difficult to achieve efficient and accurate online testing.
The system employs a moving electromagnetic box to generate a moving magnetic field to excite defects within the wire rope. Combined with a non-contact weak magnetic sensing sensor and a dynamically adjustable detection probe, the system achieves real-time adjustment of the detection probe through the cooperation of a bidirectional lead screw and a servo motor. Electrostatic dust removal and a steady-state wheel ensure the accuracy and stability of the detection.
It enables efficient and accurate testing of wire ropes on high-speed production lines, improving the reliability of test results and production safety, reducing testing errors, and ensuring the flexibility and adaptability of testing equipment.
Smart Images
Figure CN223784255U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of wire rope testing technology, and in particular to an online wire rope testing device. Background Technology
[0002] In the highly automated process of modern industry, the stable operation of machinery depends on the reliability and safety of its various components. As a crucial component, the quality of wire rope directly affects the continuity of production and the safety of personnel. Defective wire ropes are prone to breakage and wear during long-term operation, potentially leading to serious production accidents. Therefore, continuous and meticulous quality inspection of wire ropes during the production process is of paramount importance.
[0003] Currently, existing wire rope inspection methods all have varying degrees of shortcomings. Visual inspection relies on the experience and eyesight of the inspectors, which is not only inefficient but also highly subjective, making it difficult to ensure the accuracy of the results. Manual measurement, while providing relatively accurate data, is complex and time-consuming, making it unsuitable for the inspection needs of large-scale, high-speed production lines. Electromagnetic detection, although relatively advanced and using induced current to detect internal defects in wire ropes, is significantly affected by environmental factors; for example, interference from surrounding electromagnetic fields can affect detection accuracy, and the equipment is expensive and complex to maintain. While detection methods based on the magnetic memory effect can achieve inspection without interrupting production and have some application value, the extremely high sensitivity of weak magnetic sensing sensors to their placement means that improper placement can lead to inaccurate results or even render the inspection meaningless.
[0004] In summary, existing testing methods generally suffer from problems such as slow testing speed, high cost, and susceptibility to environmental interference. There is an urgent need for a new type of online wire rope testing equipment to overcome these shortcomings and improve the credibility and reliability of the testing results. Utility Model Content
[0005] To improve the reliability of the test results, this application provides an online testing device for steel wire ropes.
[0006] The online inspection device for steel wire rope provided in this application adopts the following technical solution:
[0007] An online inspection device for steel wire rope includes an inspection bracket. The steel wire rope is conveyed along the length of the inspection bracket. The inspection bracket is provided with a motion electromagnetic box that applies a moving magnetic field to the steel wire rope, an inspection component, and a winding wheel for winding the steel wire rope, arranged sequentially along the conveying direction of the steel wire rope. The inspection component includes several sets of inspection probes with non-contact weak magnetic sensing sensors. A sliding frame is slidably arranged on the inspection bracket for each set of inspection probes. Each set of inspection probes includes two probes, which are distributed on both sides of the steel wire rope and are arranged opposite each other on the top of the sliding frame. The inspection bracket is provided with an adjustment component for adjusting the spacing between the sliding frames.
[0008] By adopting the above technical solutions, the testing equipment can achieve efficient and accurate testing of wire ropes. First, the moving magnetic field generated by the moving electromagnetic box effectively excites minute defects within the wire rope, making these defects easier for the detection probe to capture under the influence of the magnetic field. Second, the application of a non-contact weak magnetic sensing sensor avoids the limitations of traditional contact testing methods, improving the reliability and accuracy of the testing. Furthermore, the sliding frame design allows the detection probe to dynamically adjust its spacing according to the wire rope's conveying speed, ensuring the probe is always in the optimal testing position, further enhancing the accuracy and stability of the testing. In summary, this equipment can achieve comprehensive and detailed testing of wire ropes on high-speed, continuous production lines, significantly improving production safety and efficiency.
[0009] Optionally, a fixing plate is provided on the side wall of the detection bracket, and one fixing plate is provided at each end of the detection bracket. Several sliding frames are located between two fixing plates. The adjustment assembly includes a bidirectional lead screw rotatably disposed between the two fixing plates, a drive block that is threadedly sleeved on the threaded section of the bidirectional lead screw, and a servo motor that drives the bidirectional lead screw to rotate. The axial direction of the bidirectional lead screw is parallel to the length direction of the detection bracket. One drive block is provided for each threaded section of the bidirectional lead screw and is connected to the sliding frame near the fixing plate.
[0010] By adopting the above technical solution, the combined use of the bidirectional lead screw and servo motor allows the sliding frame spacing to be adjusted in real time according to the actual conveying speed of the wire rope, thereby ensuring that the detection probe is always in optimal working condition and reducing detection errors caused by changes in the wire rope's moving speed. This achieves dynamic adjustment of the detection component spacing, improving the flexibility and adaptability of the detection process.
[0011] Optionally, the adjustment assembly further includes a compression spring connected between two adjacent slide frames, with the axes of several compression springs located on the same side of the detection bracket along the length direction coinciding.
[0012] By adopting the above technical solution, the compression spring ensures a constant distance between adjacent sliding frames, thereby guaranteeing the uniform distribution of the detection probes on both sides of the wire rope. When the wire rope conveying speed changes, the compression spring can generate corresponding elastic force adjustments between the sliding frames, ensuring that the detection probes are always in the optimal detection position, thus improving the accuracy and stability of the detection results.
[0013] Optionally, a guide rod is connected between two fixed plates on the side of the detection bracket away from the bidirectional lead screw. The guide rod is parallel to the length direction of the detection bracket, and multiple guide blocks are slidably arranged on the guide rod. The guide blocks correspond one-to-one with the sliding frame and are connected to the sliding frame.
[0014] By adopting the above technical solution, the guide rod design enables the sliding frame to maintain stable linear motion when adjusting the spacing, avoiding detection errors caused by lateral displacement.
[0015] Optionally, the detection bracket has a vertically arranged through hole along its own length, the length of the through hole matching the distance between the two fixed plates, and a marking stamp is raised and lowered on each sliding frame. The marking stamp passes through the through hole and is located directly below the wire rope.
[0016] By adopting the above technical solution, when the detection component detects a defect in the wire rope, the marking stamp can promptly mark the corresponding defect location, facilitating subsequent precise positioning and treatment of the defect and improving the intuitiveness and practicality of the detection results. Simultaneously, the through-hole design allows the marking stamp to be applied without affecting the normal transport of the wire rope, ensuring the continuity and stability of the detection process.
[0017] Optionally, the feed end of the detection bracket is provided with a stabilizing component, which includes a stabilizing support and a stabilizing wheel rotatably mounted on the stabilizing support. The axial direction of the stabilizing wheel is perpendicular to the length direction of the detection bracket, and the wire rope is inserted into the stabilizing wheel during transmission.
[0018] By adopting the above technical solution, the axis of the steady-state pulley is perpendicular to the length direction of the testing bracket, ensuring that the wire rope remains straight during transmission and preventing the impact on testing accuracy due to wire rope vibration or deviation from the track. Simultaneously, the rotational design of the steady-state pulley reduces the friction between the wire rope and the testing equipment, lowering the risk of surface damage to the wire rope and further improving the reliability of the testing and the accuracy of the results.
[0019] Optionally, the detection bracket is equipped with an electrostatic dust removal box, which is located between the steady-state component and the moving electromagnetic box, and the steel wire rope passes through the electrostatic dust removal box during the transmission process.
[0020] By adopting the above technical solution, surface dust and other impurities can be effectively removed before the wire rope enters the testing area, thereby avoiding the impact of these impurities on the subsequent testing results and improving the accuracy and reliability of the testing.
[0021] Optionally, a protective box is fitted onto the winding reel, and the protective box has an inlet for the wire rope to enter.
[0022] By adopting the above technical solution, the protective box fitted on the winding reel can effectively prevent external impurities from entering during the wire rope winding process, keeping the wire rope clean and thus improving the accuracy and reliability of the test results. At the same time, the rope inlet design on the protective box ensures that the wire rope enters the winding reel smoothly, avoiding wire rope damage or jamming caused by obstructed rope entry path.
[0023] In summary, this application includes at least one of the following beneficial technical effects:
[0024] 1. The testing equipment enables efficient and accurate inspection of wire ropes. Firstly, the moving magnetic field generated by the electromagnetic box effectively excites minute defects within the wire rope, making them easier for the detection probe to capture under the influence of the magnetic field. Secondly, the application of a non-contact weak magnetic sensing sensor avoids the limitations of traditional contact-based testing methods, improving the reliability and accuracy of the inspection. Furthermore, the sliding frame design allows the detection probe to dynamically adjust its spacing according to the wire rope's conveying speed, ensuring the probe is always in the optimal detection position, further enhancing the accuracy and stability of the inspection. In summary, this equipment enables comprehensive and detailed inspection of wire ropes on high-speed, continuous production lines, significantly improving production safety and efficiency.
[0025] 2. The combined use of a bidirectional lead screw and a servo motor allows the sliding frame spacing to be adjusted in real time according to the actual conveying speed of the wire rope, ensuring that the detection probe is always in optimal working condition and reducing detection errors caused by changes in the wire rope's movement speed. This achieves dynamic adjustment of the detection component spacing, improving the flexibility and adaptability of the detection process.
[0026] 3. The compression spring ensures a constant distance between adjacent sliding frames, guaranteeing uniform distribution of the detection probes on both sides of the wire rope. When the wire rope conveying speed changes, the compression spring generates corresponding elastic force adjustments between the sliding frames, ensuring the detection probes are always in the optimal detection position, thus improving the accuracy and stability of the detection results. Attached Figure Description
[0027] Figure 1 This is a schematic diagram of the overall structure of an embodiment of this application.
[0028] Figure 2 This is a cross-sectional view of the overall structure of an embodiment of this application.
[0029] Figure 3 This is a schematic diagram illustrating the connection relationship between the guide rod, the sliding frame, and the detection bracket in the embodiments of this application.
[0030] Explanation of reference numerals in the attached figures:
[0031] 01. Wire rope; 1. Detection bracket; 11. Fixing plate; 12. Guide rod; 121. Guide block; 13. Through hole; 2. Steady-state assembly; 21. Steady-state support; 22. Steady-state wheel; 3. Electrostatic dust collector; 4. Motion electromagnetic box; 5. Detection assembly; 51. Detection probe; 6. Winding wheel; 61. Protective box; 611. Rope inlet; 7. Sliding frame; 71. Electric pusher cylinder; 8. Adjustment assembly; 81. Bidirectional lead screw; 82. Drive block; 83. Servo motor; 84. Compression spring; 9. Marking stamp. Detailed Implementation
[0032] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.
[0033] This application discloses an online inspection device for steel wire ropes.
[0034] Reference Figure 1 and Figure 2 A wire rope online inspection device includes an inspection bracket 1. Along the conveying direction of the wire rope 01, a steady-state component 2, an electrostatic dust removal box 3, a motion electromagnetic box 4, an inspection component 5, and a winding wheel 6 are sequentially installed on the inspection bracket 1.
[0035] Reference Figure 1 and Figure 2 The steel wire rope 01 is conveyed along the length of the detection bracket 1, passing through the steady-state component 2, the electrostatic dust removal box 3, the motion electromagnetic box 4 and the detection component 5 in sequence, and finally wound up on the winding wheel 6.
[0036] Reference Figure 1 The steady-state component 2 includes a steady-state support 21 and a steady-state wheel 22. The steady-state wheel 22 is rotatably mounted on the steady-state support 21, and the axial direction of the steady-state wheel 22 is perpendicular to the length direction of the detection bracket 1. The wire rope 01 is inserted into the steady-state wheel 22 during transmission.
[0037] Reference Figure 1 The electrostatic dust removal box 3 is commercially available. Existing technology usually includes a corona discharge device and a dust collection plate inside. The corona discharge device can generate a high-voltage electric field, which charges the dust particles on the surface of the wire rope 01, and then they are adsorbed by the dust collection plate, thereby achieving the purpose of cleaning the wire rope 01.
[0038] Reference Figure 1The motion electromagnetic box 4 is commercially available and can be purchased directly. Existing technology typically includes an electromagnet and a power module inside, which are used to apply a motion magnetic field to the wire rope 01.
[0039] Reference Figure 1 The detection component 5 includes several sets of detection probes 51 with non-contact weak magnetic sensing sensors. A sliding frame 7 is slidably arranged on the detection bracket 1 for each set of detection probes 51. Each set of detection probes 51 includes two probes, which are distributed on both sides of the wire rope 01 and are fixedly arranged on the top of the adjusting sliding frame 7.
[0040] Reference Figure 1 A fixing plate 11 is fixedly installed on the side wall of the detection bracket 1. One fixing plate 11 is located at each end of the side wall of the detection bracket 1. Several sliding frames 7 are located between two fixing plates 11. An adjustment assembly 8 is installed on the detection bracket 1. The adjustment assembly 8 includes a bidirectional lead screw 81, a drive block 82, a servo motor 83, and a compression spring 84. The bidirectional lead screw 81 is rotatably mounted between the two fixing plates 11 parallel to the length direction of the detection bracket 1. The drive block 82 is fixedly mounted on the sliding frame 7 near the fixing plate 11, and is provided for each thread segment of the bidirectional lead screw 81, and is fitted onto the thread segment of the bidirectional lead screw 81 through thread rotation. The servo motor 83 is fixedly mounted on the side wall of one of the fixing plates 11 opposite to the bidirectional lead screw 81, and its output shaft rotatably passes through the fixing plate 11 and is coaxially fixedly connected to the bidirectional lead screw 81.
[0041] Reference Figure 1 The compression spring 84 is connected between two adjacent sliding frames 7, and the axes of several compression springs 84 located on the same side of the length direction of the detection bracket 1 coincide.
[0042] Reference Figure 1 and Figure 3 To avoid detection errors caused by lateral displacement of the sliding frame 7, a guide rod 12 is connected between two fixed plates 11 on the side of the detection bracket 1 away from the bidirectional lead screw 81. The guide rod 12 is parallel to the length direction of the detection bracket 1, and multiple guide blocks 121 are slidably arranged on the guide rod 12. In this embodiment, two guide blocks are used as an example. Each guide block 121 corresponds to a single sliding frame 7 close to the fixed plate 11 and is fixedly arranged on the corresponding sliding frame 7.
[0043] Reference Figure 1 and Figure 3 In order to mark the defects of the wire rope 01 for subsequent processing and recording, each sliding frame 7 is equipped with a marking stamp 9 which is raised and lowered by an electric push cylinder 71. The detection bracket 1 has a vertical through hole 13 along its own length direction. The length of the through hole 13 matches the distance between the two fixing plates 11. The marking stamp 9 passes through the through hole 13 and is located directly below the wire rope 01.
[0044] Reference Figure 1 A protective box 61 is fitted on the winding reel 6. The protective box 61 is fixedly mounted on the detection bracket 1, and the protective box 61 has a rope inlet 611 for the steel wire rope 01 to enter.
[0045] The implementation principle of the online steel wire rope inspection device in this application embodiment is as follows: the end of the steel wire rope 01 being inspected enters the inspection bracket 1 from the steady wheel 22 and passes through the electrostatic dust removal box 3 to remove surface dust; then it passes through the motion electromagnetic box 4 and is subjected to a motion magnetic field. Because the motion magnetic field generated by the motion electromagnetic box 4 can effectively excite the tiny defects in the steel wire rope 01, these defects are more easily captured by the inspection probe 51 under the action of the magnetic field; then the steel wire rope 01 passes between multiple sets of inspection probes 51 during the transmission process to perform online defect detection of the steel wire rope 01.
[0046] When the detection probe 51 detects a defect in the wire rope 01, the corresponding marking stamp 9 can mark the corresponding defect location in a timely manner, which facilitates the accurate positioning and treatment of the defect in the future.
[0047] To ensure that the detection probe 51 is always in the optimal detection position, the cooperation of the bidirectional lead screw 81 and the servo motor 83 allows the spacing of the slide frame 7 to be adjusted in real time according to the actual conveying speed of the wire rope 01. At the same time, the compression spring 84 can generate corresponding elastic force adjustment between the slide frames 7 to ensure that the detection probe 51 is always in the optimal detection position, thereby improving the accuracy and stability of the detection results.
[0048] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. An online inspection device for steel wire ropes, characterized in that... The system includes a detection bracket (1), a steel wire rope (01) is conveyed along the length of the detection bracket (1), and the detection bracket (1) is provided with a motion electromagnetic box (4) that applies a motion magnetic field to the steel wire rope (01), a detection component (5), and a winding wheel (6) for winding the steel wire rope (01) in sequence along the conveying direction of the steel wire rope (01). The detection component (5) includes several sets of detection probes (51) with non-contact weak magnetic sensing sensors, and a sliding frame (7) is slidably provided on the detection bracket (1) for each set of detection probes (51). Each set of detection probes (51) includes two probes, which are distributed on both sides of the steel wire rope (01) and are arranged opposite each other on the top of the adjusting sliding frame (7). The detection bracket (1) is provided with an adjusting component (8) for adjusting the spacing of the adjusting sliding frames (7).
2. The online inspection device for steel wire rope according to claim 1, characterized in that... The detection bracket (1) is provided with a fixing plate (11) on its side wall. Each fixing plate (11) is located at one end of the detection bracket (1). Several sliding frames (7) are located between two fixing plates (11). The adjustment component (8) includes a bidirectional lead screw (81) rotatably disposed between two fixing plates (11), a drive block (82) rotatably sleeved on the threaded section of the bidirectional lead screw (81), and a servo motor (83) that drives the bidirectional lead screw (81) to rotate. The axial direction of the bidirectional lead screw (81) is parallel to the length direction of the detection bracket (1). Each drive block (82) is provided for each threaded section of the bidirectional lead screw (81) and is connected to the sliding frame (7) near the fixing plate (11).
3. The online inspection device for steel wire rope according to claim 2, characterized in that... The adjustment assembly (8) also includes a compression spring (84) connected between two adjacent slide frames (7), and the axes of several compression springs (84) located on the same side of the length direction of the detection bracket (1) coincide.
4. The online inspection device for steel wire rope according to claim 2, characterized in that... A guide rod (12) is connected between two fixing plates (11) on the side away from the bidirectional lead screw (81) of the detection bracket (1). The guide rod (12) is parallel to the length direction of the detection bracket (1), and multiple guide blocks (121) are slidably arranged on the guide rod (12). The guide blocks (121) correspond one-to-one with the slide frame (7) and are connected to the slide frame (7).
5. The online inspection device for steel wire rope according to claim 2, characterized in that... The detection bracket (1) has a vertically arranged through hole (13) along its own length direction. The length of the through hole (13) matches the distance between the two fixing plates (11). Each sliding frame (7) has a rising and falling marking stamp (9). The marking stamp (9) passes through the through hole (13) and is located directly below the wire rope (01).
6. The online inspection device for steel wire rope according to claim 1, characterized in that... The feed end of the detection bracket (1) is provided with a stabilizing component (2). The stabilizing component (2) includes a stabilizing support (21) and a stabilizing wheel (22) rotatably mounted on the stabilizing support (21). The axial direction of the stabilizing wheel (22) is perpendicular to the length direction of the detection bracket (1). The wire rope (01) is inserted into the stabilizing wheel (22) during transmission.
7. The online inspection device for steel wire rope according to claim 5, characterized in that... The detection bracket (1) is provided with an electrostatic dust removal box (3), which is located between the steady-state component (2) and the moving electromagnetic box (4). The steel wire rope (01) passes through the electrostatic dust removal box (3) during the transmission process.
8. The online inspection device for steel wire rope according to claim 1, characterized in that... The winding reel (6) is fitted with a protective box (61), and the protective box (61) has a rope inlet (611) for the wire rope (01) to enter.