Multi-channel steel wire rope row nondestructive flaw detector

Abstract

The utility model provides a multichannel nondestructive flaw detector for a steel wire rope row, which relates to the field of nondestructive detection of electromechanical equipment and comprises a pulley, a nondestructive flaw detector arranged on the front surface of the pulley and the steel wire rope row arranged between the pulley and the nondestructive flaw detector, the nondestructive flaw detector comprises a sensor guide sleeve module arranged on the front surface of the pulley; according to the modularized sensor guide sleeve module, rapid replacement is supported, the detection efficiency is remarkably improved, double guarantee is achieved through the pressing and fixing device and the adjustable counter wheel, the high-altitude operation risk is avoided, multi-channel continuous collection is combined with automatic analysis, manual intervention is reduced, the detection precision is improved, and the detection efficiency is improved. The problems of low detection efficiency and data fragmentation of multiple long-distance steel wire rope rows are solved, regular detection and real-time monitoring are supported, the health state of the multiple steel wire rope rows is accurately evaluated, equipment damage and production loss caused by sudden damage of the multiple steel wire rope rows are avoided, and the method is particularly suitable for high-strength and high-frequency operation scenes.

Description

Technical Field

[0001] This utility model belongs to the field of non-destructive testing of electromechanical equipment, specifically a multi-channel steel wire rope non-destructive testing instrument. Background Technology

[0002] As a core load-bearing component of key equipment such as lifting machinery, mine hoisting, and bridge cables, the early detection of internal defects of steel wire ropes is directly related to the safety of equipment operation. In the process of building a green and intelligent oilfield, the large-scale application of high-efficiency integrated single-machine driven multi-well oil production system has become an inevitable trend in oilfield equipment upgrading. The power transmission center of this system adopts a multi-wire rope transmission array with pulley block traction as the core actuator.

[0003] Under long-term alternating load conditions, wire rope bars are prone to progressive damage such as microcrack propagation and metal cross-sectional loss due to periodic bending stress and contact fatigue effects, which eventually leads to sudden fracture failure. In view of the above working conditions, the transmission system of multiple wire rope bars is defined as a critical vulnerable functional unit. Its random fracture event will not only cause the interruption of oil production operations, but may also trigger a chain of failures in the transmission system, seriously affecting the overall operational safety of the equipment.

[0004] In summary, this utility model provides a multi-channel wire rope non-destructive testing instrument to solve the above problems. Utility Model Content

[0005] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0006] A multi-channel wire rope non-destructive testing instrument includes a pulley, a non-destructive testing instrument disposed on the front of the pulley, and a wire rope strip disposed between the pulley and the non-destructive testing instrument.

[0007] The non-destructive testing instrument includes a sensor guide sleeve module disposed on the front of the pulley, a clamping and fixing device disposed on the top of the sensor guide sleeve module, a counting wheel disposed on the front of the sensor guide sleeve module, and a signal processing unit disposed on the bottom of the sensor guide sleeve module.

[0008] Furthermore, in this invention, the steel wire ropes are arranged in rows and pass around the pulleys, and are slidably connected to the surface of the pulleys. Each steel wire rope in the row extends individually into the sensor guide sleeve module.

[0009] Furthermore, in this utility model, the sensor guide sleeve module is a modular design, containing eight rope grooves, the groove width and number of grooves are adjustable, and it is suitable for steel wire ropes with a diameter of Φ8-18mm.

[0010] Furthermore, in this utility model, the clamping and fixing device is located on the side of the sensor guide sleeve module, and has a built-in elastic clamping mechanism composed of a cylindrical helical spring and a stroke limit block, which can adapt to the clamping requirements of multiple steel wire ropes of different diameters.

[0011] Furthermore, in this invention, the counting wheel is hinged to the sensor guide sleeve module, and the state of the wire rope can be adjusted by a lifting mechanism consisting of a motor and a ball screw pair.

[0012] Furthermore, in this invention, the signal processing unit integrates a high-precision magnetic flux leakage sensor and a built-in filtering and noise reduction module, and transmits data to an external analysis system in real time via Wi-Fi to collect wire rope defect signals in real time.

[0013] Beneficial effects: This utility model has the following beneficial effects:

[0014] This utility model's modular sensor guide sleeve module supports quick replacement, significantly improving detection efficiency. The clamping and fixing device and adjustable counting wheel provide dual protection, avoiding the risks of working at heights. Multi-channel continuous acquisition combined with automated analysis reduces manual intervention, improves detection accuracy, reduces the need for specialized accessories, and lowers maintenance costs. It solves the problems of low detection efficiency and fragmented data for multiple long-distance steel wire rope arrays. It supports regular inspection and real-time monitoring, accurately assessing the health status of multiple steel wire rope arrays and avoiding equipment damage and production losses caused by sudden failures of multiple steel wire rope arrays. It is especially suitable for high-intensity, high-frequency operation scenarios. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the main structure of the non-destructive testing instrument of this utility model;

[0016] Figure 2 This is a flowchart of the workflow of this utility model;

[0017] Figure 3 This is a flowchart of the workflow of this utility model;

[0018] Figure 4 This is a schematic diagram of the main structure of this utility model.

[0019] In the picture:

[0020] 1. Pulley; 2. Non-destructive testing instrument; 21. Sensor guide sleeve module; 22. Clamping and fixing device; 23. Counting wheel; 24. Signal processing unit; 3. Steel wire rope row. Detailed Implementation

[0021] To better understand the technical content of this utility model, specific embodiments are described below in conjunction with the accompanying drawings. Various aspects of this utility model are described in this disclosure with reference to the accompanying drawings, which illustrate numerous illustrative embodiments. The embodiments of this disclosure are not necessarily defined to include all aspects of this utility model. It should be understood that the various concepts and embodiments described above, as well as those described in more detail below, can be implemented in any of many ways, because the concepts and embodiments disclosed in this utility model are not limited to any particular implementation. Furthermore, some aspects of this utility model can be used alone or in any suitable combination with other aspects disclosed in this utility model.

[0022] Example 1

[0023] like Figure 1-4 As shown, this is the first embodiment of the present invention. This embodiment provides a multi-channel wire rope non-destructive testing instrument, including a pulley 1, a non-destructive testing instrument 2 disposed on the front of the pulley 1, and a wire rope row 3 disposed between the pulley 1 and the non-destructive testing instrument 2.

[0024] The non-destructive testing instrument 2 includes a sensor guide sleeve module 21 disposed on the front of the pulley 1, a clamping and fixing device 22 disposed on the top of the sensor guide sleeve module 21, a counting wheel 23 disposed on the front of the sensor guide sleeve module 21, and a signal processing unit 24 disposed on the bottom of the sensor guide sleeve module 21.

[0025] like Figure 1-4 As shown, the detachable sensor guide sleeve module 21 contains eight rope grooves, the width and number of which can be adjusted according to requirements, and is suitable for steel wire ropes with diameters of Φ8-18mm. The sensor guide sleeve module 21 is modularly designed and supports quick replacement to adapt to multi-strand steel wire rope rows 3 of different diameters. The clamping and fixing device 22 is used to clamp the steel wire rope row 3 to prevent the equipment from falling from a height. The counting wheel 23 is height adjustable, allowing the counting wheel 23 to switch between contact and separation states with the multi-strand steel wire rope row 3. The signal processing unit 24 analyzes the data in real time and uses a magnetic flux change rate algorithm to identify defects such as broken wires and wear, triggering audible and visual alarms according to the defect level.

[0026] Example 2

[0027] Reference Figure 1 and 4 This is the second embodiment of the present invention, which is based on the previous embodiment.

[0028] In this embodiment, the steel wire ropes 3 are arranged in rows and pass around the pulley 1 and are slidably connected to the surface of the pulley 1. Each steel wire rope in the steel wire rope row 3 extends into the sensor guide sleeve module 21 individually.

[0029] The sensor guide sleeve module 21 is a modular design, containing eight rope grooves. The groove width and number of grooves are adjustable, and it is suitable for steel wire ropes with a diameter of Φ8-18mm.

[0030] like Figure 1 and 4 As shown, the steel wire ropes 3 are arranged in rows and pass around the pulley 1. The non-destructive testing instrument 2 is installed on the steel wire ropes 3 extending from the pulley 1. Each steel wire rope in the steel wire ropes 3 is individually inserted into the sensor guide sleeve module 21 of the non-destructive testing instrument 2, thereby simultaneously detecting the wear condition of each steel wire rope in the steel wire ropes 3. At the same time, the steel wire ropes 3 are pressed and fixed by the clamping and fixing device 22 of the non-destructive testing instrument 2 to prevent the non-destructive testing instrument 2 from falling from a height. The modular sensor guide sleeve module 21 supports quick replacement, significantly improving the detection efficiency.

[0031] Example 3

[0032] Reference Figure 1 and 4 This is the third embodiment of the present invention, which is based on the first two embodiments.

[0033] In this embodiment, the clamping and fixing device 22 is located on the side of the sensor guide sleeve module 21, and has a built-in elastic clamping mechanism composed of a cylindrical helical spring and a stroke limit block, which can adapt to the clamping requirements of multiple steel wire ropes of different diameters.

[0034] The counting wheel 23 is hinged to the sensor guide sleeve module 21, and the state of the wire rope row 3 can be adjusted by a lifting mechanism consisting of a motor and a ball screw pair.

[0035] The signal processing unit 24 integrates a high-precision magnetic leakage sensor and has a built-in filtering and noise reduction module. It transmits data to an external analysis system in real time via Wi-Fi to collect wire rope defect signals in real time.

[0036] like Figure 1 and 4 As shown, the clamping and fixing device 22 is used to clamp the wire rope row 3 to prevent the equipment from falling from a height. The counting wheel 23 is height adjustable, so that the counting wheel 23 can switch between two states of contact and separation with the multi-strand wire rope row 3. The signal processing unit 24 analyzes the data in real time, uses the magnetic flux change rate algorithm to identify defects such as broken wires and wear, triggers audible and visual alarms according to the defect level, and generates a comprehensive report including the defect location, level and replacement suggestions.

[0037] In use, the wire ropes 3 are arranged in rows and pass around the pulley 1. The non-destructive testing instrument 2 is installed on the wire ropes 3 extending from the pulley 1. Each wire rope in the wire ropes 3 is individually inserted into the sensor guide sleeve module 21 of the non-destructive testing instrument 2, thereby simultaneously detecting the wear condition of each wire rope in the wire ropes 3. The wire ropes 3 are pressed and fixed by the clamping and fixing device 22 of the non-destructive testing instrument 2 to prevent the non-destructive testing instrument 2 from falling from a height. The sensor guide sleeve module 21 is installed at point A of the multiple parallel wire ropes 3. After the clamping and fixing device 22 is locked, the motor is started to drive the counting wheel 23 to rotate, so that the non-destructive testing instrument 2 moves from point A to point B and collects the leakage magnetic signal in real time. After pulling out the steel wire rope at end C, the non-destructive testing instrument 2 continues to move from point B to point C to complete the coverage inspection of the entire steel wire rope. The signal processing unit 24 analyzes the data in real time, uses the magnetic flux change rate algorithm to identify defects such as broken wires and wear, triggers audible and visual alarms according to the defect level, and generates a comprehensive report including the defect location, level and replacement suggestions.

[0038] All standard parts used in this application can be purchased from the market, and can be customized according to the description and drawings. The specific connection methods of each part adopt conventional methods such as bolts, rivets, and welding that are mature in the prior art. The machinery, parts and equipment adopt conventional models in the prior art. The control method is automatic control through a controller. The control circuit of the controller can be implemented by simple programming by those skilled in the art and is common knowledge in the field. Since this application is mainly used to protect mechanical devices, the control method and circuit connection will not be explained in detail in this application.

[0039] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Those skilled in the art to which this invention pertains can make various modifications and refinements without departing from the spirit and scope of the present invention. Therefore, the scope of protection of this invention shall be determined by the claims.

Claims

1. A multi-channel non-destructive testing instrument for steel wire rope, characterized in that: It includes a pulley (1), a non-destructive testing instrument (2) disposed on the front of the pulley (1), and a steel wire rope row (3) disposed between the pulley (1) and the non-destructive testing instrument (2); The non-destructive testing instrument (2) includes a sensor guide sleeve module (21) disposed on the front of the pulley (1), a clamping and fixing device (22) disposed on the top of the sensor guide sleeve module (21), a counting wheel (23) disposed on the front of the sensor guide sleeve module (21), and a signal processing unit (24) disposed on the bottom of the sensor guide sleeve module (21).

2. The multi-channel steel wire rope non-destructive testing instrument as described in claim 1, characterized in that: The steel wire ropes (3) are arranged in rows around the pulley (1) and are slidably connected to the surface of the pulley (1). Each steel wire rope of the steel wire ropes (3) extends into the sensor guide sleeve module (21) individually.

3. The multi-channel steel wire rope non-destructive testing instrument as described in claim 1, characterized in that: The sensor guide sleeve module (21) is a modular design, containing eight rope grooves. The groove width and number of grooves are adjustable, and it is suitable for steel wire ropes with a diameter of Φ8-18mm.

4. The multi-channel steel wire rope non-destructive testing instrument as described in claim 1, characterized in that: The clamping and fixing device (22) is located on the side of the sensor guide sleeve module (21), and has a built-in elastic clamping mechanism consisting of a cylindrical helical spring and a stroke limit block, which can adapt to the clamping requirements of multiple steel wire ropes of different diameters.

5. The multi-channel steel wire rope non-destructive testing instrument as described in claim 1, characterized in that: The counting wheel (23) is hinged to the sensor guide sleeve module (21), and the state of the wire rope row (3) can be adjusted by a lifting mechanism consisting of a motor and a ball screw pair.

6. The multi-channel steel wire rope non-destructive testing instrument as described in claim 1, characterized in that: The signal processing unit (24) integrates a high-precision magnetic leakage sensor and has a built-in filtering and noise reduction module. It transmits data to an external analysis system in real time via Wi-Fi and collects wire rope defect signals in real time.

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