Magnetoresistive Sensor Array for Steel Wire Rope Damage Detection
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Solution Overview
Problem
Current electromagnetic non-destructive testing methods for steel wire ropes face challenges in detecting internal damage due to magnetic saturation issues with increased excitation fields and poor spatial resolution with lower excitation fields, requiring reference signals for data comparison.
Innovation Solution
A non-destructive testing device utilizing a magnetoresistive sensor array that measures magnetic field gradients without excitation, leveraging the magnetic memory of steel wire ropes and using a single chip microcomputer to calculate differential signals for damage detection, eliminating the need for an excitation structure and reference signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the excitation field is increased to strengthen the leakage magnetic field for internal damage detection, then the detection capability is improved, but the magnetic sensor reaches magnetic saturation and loses sensitivity
Solution Approach 1:
Instead of using an external excitation field to generate leakage magnetic fields for detection, the patent inverts the approach by utilizing the steel wire rope's own magnetic memory (residual magnetization) as the detection basis. The magnetoresistive sensor array directly measures changes in the magnetic field generated by the wire rope's inherent magnetization, eliminating the need for external excitation and avoiding magnetic saturation issues.
Solution Approach 2:
The steel wire rope serves itself as both the object being detected and the source of the magnetic field for detection. The wire rope's own magnetic properties (magnetic memory) are utilized to enable self-detection without requiring external excitation structures or reference signals, thereby avoiding the limitations of conventional methods.
2Reliability
If the excitation field is decreased to maintain magnetic sensor sensitivity, then the magnetic field sensitivity is preserved, but the spatial resolution becomes insufficient and detection reproducibility deteriorates
Solution Approach 1:
The patent eliminates the excitation field dependency by using the wire rope's inherent magnetic memory. The magnetoresistive sensor array directly detects changes in the magnetic field generated by the wire rope's own magnetization, achieving both high sensitivity and high spatial resolution without the trade-off present in conventional methods.
Solution Approach 2:
The patent changes the detection parameter from measuring leakage magnetic fields (which require external excitation) to measuring changes in the wire rope's own magnetic field properties. This parameter change enables simultaneous achievement of high sensitivity and high spatial resolution by directly detecting magnetic field variations at damage locations.
3Productivity
If conventional electromagnetic detection methods are used, then detection can be performed, but reference signals and standard test blocks are required, increasing device complexity and operation complexity
Solution Approach 1:
The wire rope performs self-detection by utilizing its own magnetic memory as the detection basis. The magnetoresistive sensor array measures changes in the wire rope's inherent magnetic field, eliminating the need for external reference signals or standard test blocks. This self-service approach significantly simplifies the detection system and operation procedures.
Solution Approach 2:
The patent extracts and utilizes the wire rope's own magnetic properties (magnetic memory) as the detection basis, removing the dependency on external reference signals and standard test blocks. This extraction of the object's inherent properties enables direct detection without additional reference components.
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
The solution provides high sensitivity and spatial resolution for detecting damage, improving the detection of broken wires and deep damage, with simplified operation and direct data interpretation, suitable for various steel wire rope sizes and ferromagnetic materials.
Implementation Method 1
The present invention utilizes magnetic memory of the steel wire rope formed during use for real-time detection
Implementation Method 2
A magnetoresistive sensor array composed of N magnetoresistive sensors is arranged inside the air bag
Data Source
AI summary
A non-destructive testing device for detecting damage to a steel wire rope, including a bushing which limits a lower shell and an upper shell through a limiting groove. The lower shell is connected to the upper shell via an opening and closing structure. An air bag is wrapped around the bushing. A PCB is fixed on the upper shell or the lower shell. The PCB is connected to a guide wheel via an electrical connector. A magnetoresistive sensor array is arranged inside the air bag and is uniformly arranged in a circumferential direction of the bushing. A steel wire rope passes through the magnetoresistive sensor array. And when the steel wire rope moves, it drives the guide wheel to rotate and triggers the acquisition of a command. Guide wheel is set with a position coder which is used to calculate a relative position of movement of the steel wire rope. The PCB is connected to a single chip microcomputer via a peripheral interface. And the single chip microcomputer is used to calculate a differential signal of N adjacent magnetoresistive sensors and to determine whether the steel wire rope is damaged. The capability of this non-destructive testing device for detection of a broken wire, a narrowed diameter, and deep damage of the steel wire rope is improved.