A wire rope broken wire detection device

Abstract

The utility model discloses a kind of steel wire rope broken wire detection devices, the device includes detection mechanism shell, excitation unit, magnetic induction sensor array, signal processing unit, alarm module, encoder mechanism and marking execution mechanism.The detection mechanism shell is equipped with the passage for steel wire rope to pass through;The magnetic induction sensor array is evenly arranged in the shell inner wall, for all-around collection steel wire rope surface magnetic field signal;A pair of excitation unit is symmetrically arranged in the shell outside two sides, and the steel wire rope is saturated magnetization.The signal processing unit receives sensor signal and processes and threshold comparison, to judge whether broken wire occurs and triggers alarm.The utility model structure is compact, low in cost, can efficiently, accurately to the steel wire rope in movement carry out online, real-time broken wire detection, especially suitable for integrated into production line, greatly improve production efficiency and security.

Description

Technical Field

[0001] This utility model relates to the field of wire rope testing technology, specifically to a wire rope broken wire detection device. Background Technology

[0002] Steel wire ropes, as an important load-bearing component, are widely used in elevators, mines, cranes, cableways, and other fields. Their safety is paramount, and broken wires are one of the most common and dangerous forms of damage to steel wire ropes. Currently, steel wire rope inspections are mostly carried out manually using handheld equipment after the machine has stopped, which is inefficient and prone to missing any instances.

[0003] While some automated detection devices based on magnetic flux leakage (MFL) or machine vision exist, they are typically complex in structure, expensive, or unsuitable for integration into high-speed production lines for online real-time detection. During production, wire ropes are in a dynamic, high-speed moving state, making it difficult for traditional detection devices to reliably and stably capture broken wire signals, and they are also susceptible to environmental interference. Therefore, there is an urgent need for an online wire rope broken wire detection device that is simple in structure, low in cost, easy to integrate, and adaptable to the high-speed operating environment of production lines. Utility Model Content

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a wire rope broken wire detection device that is compact in structure, accurate in detection, fast in response speed and easy to integrate into the production line, so as to realize online, real-time, automatic marking and automated broken wire detection of moving wire ropes.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is: a wire rope broken wire detection device, the innovation of which is that it includes: The testing mechanism housing has an internal channel for steel wire ropes to pass through; At least three magnetic induction sensor arrays are evenly arranged circumferentially on the inner wall of the detection mechanism housing and directly facing the channel; A pair of excitation units, symmetrically arranged on both sides of the outer side of the detection mechanism housing, are used to magnetize the steel wire rope passing through the channel; A signal processing unit, electrically connected to the magnetic induction sensor array, is used to receive and process sensor signals. The signal processing unit includes a microprocessor, which has a preset signal threshold for determining wire breakage. An alarm module is electrically connected to the output terminal of the signal processing unit; An encoder mechanism, electrically connected to the signal processing unit, is used to measure the moving length of the wire rope and generate a position signal; the microprocessor of the signal processing unit is configured to receive the position signal from the encoder mechanism to determine the location of the broken wire when a wire breakage is detected. A marking actuator is electrically connected to the output of the signal processing unit; the microprocessor is further configured to control the marking actuator to operate when a determined wire breakage location reaches the location of the marking actuator.

[0006] Furthermore, the magnetic induction sensor array is a Hall sensor or a giant magnetoresistive sensor.

[0007] Furthermore, the excitation unit is a permanent magnet made of neodymium iron boron.

[0008] Furthermore, the inner wall of the channel is embedded with a wear-resistant bushing, which is made of engineering plastic or copper alloy.

[0009] Furthermore, the housing of the detection mechanism is made of a non-magnetic material.

[0010] Furthermore, the non-magnetic material is aluminum alloy or stainless steel.

[0011] Furthermore, the alarm module includes an audible and visual alarm.

[0012] Furthermore, the alarm module includes a communication interface connected to the production line control system.

[0013] Furthermore, the signal processing unit also includes a signal amplifier and a filter electrically connected to the magnetic induction sensor array and the microprocessor.

[0014] Furthermore, the actuator marked is a painting device.

[0015] The beneficial effects of this utility model after adopting the above structure are as follows: This invention employs online real-time detection: it can be directly integrated into the wire rope production line to achieve 100% online detection of moving wire ropes without stopping the machine, greatly improving production efficiency.

[0016] This invention boasts high detection accuracy: by employing a circumferentially uniformly distributed sensor array, it achieves 360° detection of the wire rope without blind spots, greatly reducing the missed detection rate.

[0017] This utility model has a simple and reliable structure: the core detection components are integrated into a compact housing, which is robust, has strong anti-interference ability, and is very suitable for harsh industrial environments.

[0018] This invention offers a rapid response: the delay from signal acquisition to alarm output is extremely short, enabling instantaneous response and facilitating timely adjustments to the production line (such as marking or stopping the machine), thereby reducing waste output.

[0019] This invention is cost-effective: compared to large and complex testing equipment, this invention mainly adopts mature sensor and permanent magnet technologies, which significantly reduces manufacturing and maintenance costs.

[0020] This invention achieves precise positioning: by directly linking the detection results with the physical location, maintenance personnel do not need to rescan the entire line with handheld equipment. They can directly find the damage point for repair or cutting based on the marked points or location data, saving a lot of time and manpower. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the internal structure of this utility model.

[0022] Explanation of reference numerals in the attached figures: 1. Detection mechanism housing; 2. Channel; 3. Wear-resistant nylon bushing; 4. Magnetic induction sensor array; 5. Excitation unit; 6. Signal processing unit; 7. Audible and visual alarm; 8. RS485 communication interface; 9. Encoder mechanism; 10. Marking actuator. Detailed Implementation

[0023] The present invention will be further described below with reference to the accompanying drawings.

[0024] To make the objectives, technical solutions, and advantages of this utility model clearer, the present utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only for explaining the present utility model and are not intended to limit the present utility model.

[0025] like Figure 1 As shown, a wire rope broken wire detection device mainly consists of a detection mechanism housing 1, a signal processing unit 6, an alarm module 7, an encoder mechanism 9, and a marking execution mechanism 10.

[0026] The housing 1 of the measuring mechanism is made of a non-magnetic material, such as aluminum alloy or 304 stainless steel, to avoid interference with the magnetic field. An internal steel wire rope channel 2 runs through it from left to right, through which the steel wire rope to be tested passes at a constant speed. Wear-resistant nylon bushings 3 are embedded in the channel 2 to prevent the steel wire rope from abrading the housing.

[0027] A Hall sensor is installed every 120° along the circumference of the inner wall of the housing 1, forming three magnetic induction sensor arrays 4. These arrays directly face the surface of the wire rope and are used to sense changes in its magnetic field. On the outer sides of the housing 1, two neodymium iron boron permanent magnets are symmetrically fixed as excitation units 5 via mounting brackets. These magnets provide sufficient magnetization force to the wire rope to achieve magnetic saturation.

[0028] The signal processing unit 6 is installed inside a protective box outside the housing 1 and is connected to all Hall sensors via cables. It internally contains an operational amplifier, a low-pass filter, and an STM32 series microprocessor. The microprocessor has a preset, experimentally calibrated magnetic field strength threshold.

[0029] When a complete steel wire rope passes by, the sensor outputs a stable signal. If a broken wire occurs, the Hall sensor at that location detects a leakage magnetic field and generates a pulse signal. This signal is amplified and filtered before being sent to the microprocessor for comparison with a threshold. If the signal exceeds the threshold, the microprocessor determines it is a broken wire and immediately outputs an alarm signal through the I / O port.

[0030] The alarm module includes a field-installed audible and visual alarm 7 and an RS485 communication interface 8. The audible and visual alarm 7 immediately sounds and flashes an indicator light to alert the operator. At the same time, the communication interface 8 uploads the wire breakage signal to the central control system of the production line. The system can automatically control the production line to stop or start the marking actuator to mark the wire breakage location.

[0031] The encoder mechanism 9 maintains contact with the moving steel wire rope via a measuring wheel, which rotates as the steel wire rope moves. The encoder converts the number of rotations and the angle into electrical pulse signals, thereby accurately calculating the length of the steel wire rope's movement (i.e., position coordinates). The encoder mechanism 9 is installed at the inlet or outlet end of the detection device housing to ensure reliable contact between the measuring wheel and the steel wire rope.

[0032] The marking actuator 10 is a painting device, which includes a miniature air pump, a high-speed solenoid valve, and a nozzle. Figure 1 Only the nozzle is shown; the miniature air pump and high-speed solenoid valve are not shown. The signal processing unit 6 is electrically connected to the high-speed solenoid valve and triggers the painting by controlling the on / off time of the solenoid valve. Normally, the solenoid valve is closed when the power is off. When the microprocessor sends an extremely short pulse signal (e.g., 20-50 milliseconds), the solenoid valve opens instantly, and high-pressure gas or liquid is ejected violently, atomizing the paint and spraying it onto the surface of the wire rope to form a clear marking point. The marking actuator 10 is fixed at the outlet end of the detection device housing. Its trigger point is at a fixed distance from the measurement position of the encoder. The control system will perform compensation calculations to ensure accurate marking.

[0033] The working principle of this utility model is as follows: A pair of high-performance permanent magnets are used to saturate the moving steel wire rope. When the steel wire rope is intact, the magnetic flux distribution on its surface is uniform and stable; when the steel wire rope has a broken wire defect, a leakage magnetic field will be generated at the break point. A circumferentially arranged magnetic induction sensor array can capture this abnormal magnetic field change signal from all directions. After the signal processing unit amplifies, filters, and performs threshold comparison analysis, the microprocessor makes a wire breakage judgment and immediately triggers the alarm module, thereby achieving fast and accurate online detection. When a wire breakage occurs, the encoder mechanism 9 converts the number of rotations and angle into an electrical pulse signal, thereby accurately calculating the length of the steel wire rope movement. When the microprocessor sends an extremely short pulse signal, the solenoid valve opens instantly, and high-pressure gas or liquid is sprayed out, atomizing the paint and spraying it onto the surface of the steel wire rope to form a clear marking point.

[0034] The above description is only used to illustrate the technical solution of this utility model and is not intended to limit it. Any other modifications or equivalent substitutions made by those skilled in the art to the technical solution of this utility model, as long as they do not depart from the spirit and scope of the technical solution of this utility model, should be covered within the scope of the claims of this utility model.

Claims

1. A wire rope broken wire detection device, characterized in that, include: The testing mechanism housing has an internal channel for steel wire ropes to pass through; At least three magnetic induction sensor arrays are evenly arranged circumferentially on the inner wall of the detection mechanism housing and directly facing the channel; A pair of excitation units, symmetrically arranged on both sides of the outer side of the detection mechanism housing, are used to magnetize the steel wire rope passing through the channel; A signal processing unit, electrically connected to the magnetic induction sensor array, is used to receive and process sensor signals. The signal processing unit includes a microprocessor, which has a preset signal threshold for determining wire breakage. An alarm module is electrically connected to the output terminal of the signal processing unit; An encoder mechanism, electrically connected to the signal processing unit, is used to measure the moving length of the wire rope and generate a position signal; the microprocessor of the signal processing unit is configured to receive the position signal from the encoder mechanism to determine the location of the broken wire when a wire breakage is detected. A marking actuator is electrically connected to the output of the signal processing unit; the microprocessor is further configured to control the marking actuator to operate when a determined wire breakage location reaches the location of the marking actuator.

2. The wire rope broken wire detection device according to claim 1, characterized in that: The magnetic induction sensor array is a Hall sensor or a giant magnetoresistive sensor.

3. The wire rope broken wire detection device according to claim 1, characterized in that: The excitation unit is a permanent magnet made of neodymium iron boron.

4. The wire rope broken wire detection device according to claim 1, characterized in that: The inner wall of the channel is fitted with a wear-resistant bushing, which is made of engineering plastic or copper alloy.

5. The wire rope broken wire detection device according to claim 1, characterized in that: The housing of the detection mechanism is made of non-magnetic material.

6. The wire rope broken wire detection device according to claim 5, characterized in that: The non-magnetic material is aluminum alloy or stainless steel.

7. The wire rope broken wire detection device according to claim 1, characterized in that: The alarm module includes an audible and visual alarm.

8. The wire rope broken wire detection device according to claim 1, characterized in that: The alarm module includes a communication interface that connects to the production line control system.

9. The wire rope broken wire detection device according to claim 1, characterized in that: The signal processing unit further includes a signal amplifier and a filter electrically connected to the magnetic induction sensor array and the microprocessor.

10. The wire rope broken wire detection device according to claim 1, characterized in that: The actuator marked is a paint spraying device.

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