Magnetic Sensor Wire Rope Deterioration Prediction
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Solution Overview
Problem
Existing methods for predicting the service life of wire ropes, such as those used in crane equipment and elevator systems, do not accurately reflect the physical condition of the wire rope, leading to inadequate timing for replacement.
Innovation Solution
A deterioration prediction device and method that utilizes a magnetic sensor to detect changes in the magnetic field of the wire rope, calculates a deterioration score based on sensor signals, updates a prediction model over time, and estimates future deterioration, thereby providing a more accurate assessment of the wire rope's condition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If service life is predicted from operation history information, then prediction can be performed without detecting physical condition, but prediction accuracy does not reflect the actual wire rope state
Solution Approach 1:
The patent replaces complex mechanical inspection systems with a magnetic field-based detection system. A magnetic sensor detects changes in the magnetic field caused by wire rope deterioration, converting physical condition assessment into a simpler electromagnetic measurement process that provides accurate real-time data without complex mechanical intervention.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the wire rope and the detection system. The magnetic sensor detects magnetic field changes that occur when the wire rope deteriorates, using the magnetic field as a mediator to translate physical condition into measurable signals without direct mechanical contact or complex inspection procedures.
2Reliability
If a weakened portion is intentionally provided to detect disconnection, then replacement timing can be detected, but the method does not provide accurate prediction of actual deterioration state
Solution Approach 1:
The patent extracts the detection function from the wire rope structure itself by using a separate magnetic sensor system. Instead of modifying the wire rope with weakened portions or embedded sensors, the system externally detects magnetic field changes caused by deterioration, separating the inspection function from the structural integrity requirements.
Solution Approach 2:
The patent replaces mechanical modification of the wire rope (adding weakened portions) with a magnetic field-based detection approach. This substitution eliminates the need to physically alter the wire rope while providing reliable detection of deterioration through non-contact magnetic sensing.
3Ease of operation
If replacement is performed based on fixed schedules, then maintenance timing is simple to determine, but replacement may occur too early or too late relative to actual condition
Solution Approach 1:
The patent implements a feedback system where magnetic sensor data continuously monitors wire rope condition and feeds this information to the prediction unit. The system adjusts replacement timing predictions based on actual measured deterioration rates, creating a closed-loop system that optimizes maintenance scheduling according to real-time condition assessment rather than fixed schedules.
Solution Approach 2:
The patent transitions from static, fixed-schedule maintenance to dynamic, condition-based maintenance prediction. The prediction unit continuously updates deterioration predictions based on ongoing magnetic field measurements and updated prediction models, allowing maintenance timing to adapt dynamically to the actual deterioration rate of each wire rope.
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
This approach enables higher accuracy in predicting the service life of magnetic bodies like wire ropes, allowing for timely and appropriate maintenance, reducing the risk of failure and ensuring safety.
Implementation Method 1
a magnetic sensor configured to detect a magnetic field affected by a magnetic body as an inspection target and output a sensor signal
Data Source
AI summary
A deterioration prediction device for a magnetic material is provided with: a magnetic sensor configured to detect a magnetic field affected by a magnetic body (W) as an inspection target and outputs a sensor signal; a deterioration score calculation means (51) configured to calculate a deterioration score indicating the degree of deterioration of the magnetic body based on the sensor signal; a deterioration score storage unit (41) configured to store the deterioration score; a deterioration prediction model storage unit configured to store a deterioration prediction model indicating a change in the degree of deterioration; a deterioration prediction model update means (52) configured to update the deterioration prediction model to acquire an updated deterioration prediction model; and a deterioration score prediction means (53) configured to estimate a future deterioration score.