Hoisting Cable Magnetic Sensing for Multiple Wire Breaks
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Solution Overview
Problem
Existing methods for determining the condition of lifting ropes in lifting systems are inadequate for reliably detecting wire breaks and multiple wire breaks, especially in high-load industrial applications, leading to potential accidents due to wear and aging.
Innovation Solution
A sensor system with a control unit, data memory, and evaluation device that analyzes sensor signals using machine-learning algorithms and pattern recognition to detect wire breaks by comparing signal profiles with pre-stored reference characteristics, allowing for real-time monitoring and prediction of rope discard status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing sensor methods are used for monitoring lifting ropes, then the system structure remains simple, but the detection reliability of wire breaks and multiple wire breaks is insufficient
Solution Approach 1:
The lifting rope is divided into multiple wire strands, and the sensor device detects changes in the magnetic field caused by individual wire breaks. By segmenting the detection focus to individual wires within the rope structure, the system can reliably detect multiple wire breaks without requiring overly complex monitoring infrastructure.
Solution Approach 2:
The patent replaces mechanical inspection methods with a sensor-based detection system that measures magnetic field changes. This substitution enables non-contact monitoring of wire breaks, improving detection reliability while maintaining relatively simple system architecture through electromagnetic field interaction rather than complex mechanical sensing.
2Measurement precision
If comprehensive monitoring of multiple wire breaks is implemented, then the detection accuracy improves, but the evaluation complexity and processing requirements increase
Solution Approach 1:
The system performs preliminary actions by pre-defining characteristic values and evaluation criteria for normal rope conditions. The sensor device continuously monitors and compares detected magnetic field changes against these pre-established benchmarks, enabling accurate detection of multiple wire breaks through systematic comparison rather than complex real-time analysis.
Solution Approach 2:
The patent monitors changes in specific physical parameters (magnetic field strength, signal amplitude) that indicate wire breaks. By focusing on parameter changes rather than comprehensive structural analysis, the evaluation device achieves high detection accuracy for multiple wire breaks while maintaining manageable complexity through targeted parameter monitoring.
3Reliability
If real-time monitoring of rope condition is implemented, then the safety and reliability improve, but the data processing and evaluation requirements increase
Solution Approach 1:
The sensor device provides continuous feedback on the lifting rope condition by detecting magnetic field changes. The evaluation device processes this feedback data in real-time, comparing current measurements against stored reference data to immediately identify wire breaks. This feedback mechanism enables timely detection and response while maintaining efficient data processing through targeted analysis of critical parameters.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the detection rate and reliability of wire breaks, enabling timely replacement of lifting ropes, reducing the risk of accidents, and optimizing maintenance schedules.
Implementation Method 1
a magnetic field generated by the inductive sensor, which extends at least partially across the elevator rope
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The invention relates to a method for determining a rope condition of a hoisting rope of a hoisting system (10) and a hoisting system (10), wherein a sensor device (25), a control unit (15) with an evaluation device (40), a data interface (45) connected to the evaluation device (40) for data transmission, and a data memory (35) connected to the evaluation device (40) for data transmission, and a hoisting rope (20) with a plurality of wires are provided, wherein at least one pattern set of several pattern signal curves is stored in the data memory (35), wherein information about a wire break (B) is assigned to each pattern signal curve, wherein at least one rope section (110) of the hoisting rope (20) is moved past the sensor device (25), wherein the sensor device (25) generates a second sensor signal indicating an interaction between the sensor device (25) and the hoisting rope (20) moved past the sensor device (25). characterized,the evaluation device (40), wherein the evaluation device (40) determines a second signal profile (120) over the cable section (110), wherein the evaluation device (40) determines a wire break (B) in the cable section (110) by assigning a sample signal profile of the sample set that matches the second signal profile (120).