Online automated testing equipment for steel wire ropes

Working principle

The combined flaw detection method of magnetic flux leakage detection and permanent magnetic perturbation detection principle combination is adopted for the detection system to form a steel wire rope composite nondestructive testing technology of magnetic flux leakage detection and permanent magnetic perturbation detection combination: The defective magnetic saturation leakage and permanent magnet

perturbation phenomenon are used as its the amount of information for judgment whether the deflect to exist or not. Use magnetic flux leakage detection and permanent magnetic perturbation detection probes to capture the magnetic information amount of the defect existence, and then after high-speed multi-channel data acquisition signal processing, ultimately send the magnetic information amount into the computer

defect analysis and evaluation system to see whether there is the output defect information, completing wire rope nondestructive flaw detection.

System constitution

ZSC127S mine steel wire rope magnetic flaw detection device mainly consists of the GTC5S constant magnetic detection sensor, S18-J21400 photoelectric position encoder, detection sensor action rocker floating tracking mechanism (multi-rope sets), detection station action rack, data acquisition and processing hardware system (USB_DP/including preamplifier, filter (multi-rope sets) and A/ D converter), data acquisition and analysis software system, main control cabinet, computer signal

processing system (DAU), video surveillance systems, data control signal cable and so on.

Main technical features

1. The unique permanent magnetic excitation magnetic physics technology (By instantaneous local constant magnetic excitation, there is no magnetic force during scanning without ) is used to achieve the precise detection of wire rope broken wire, wear, corrosion, rope diameter shrinkage, deformation and loose strands and other damage and the life safe and reliable assessment.

2. The detection sensor and post-processing system have a strong anti-interference ability (for instance, the interference from mobile phones, other magnetic sources and hoisting machine electromagnetic noise), can carry out precision detection under the large shake of the rope, and the signal output - signal noise ratio is high.

3. The single-chip control system is adopted to achieve the automatic remote monitoring of the hoisting machine steel wire rope (including flaw detection and video surveillance).

4. The product technology meets the requirements in national GB/T 121837-2008 Ferromagnetic wire rope electromagnetic detection method and the American ASTME1571-2001 Standard Specification for Electromagnetic Inspection of Ferromagnetic Steel Wire Ropes.

5. Comparison between the positioning data (broken wire, corrosion, wear, loose strands, skip steel wire and so on) and day, month and historical data is achieved and reports can be printed, and the data retention time is up to 5 years.

6. Stable work, reliable performance, high detection accuracy, strong anti-jamming performance, and accurate data.

7. Software adapts to Win7 / xp / vista / win10 and above computer operating system.

Main performances and technical indexes

1.Detection of rope diameter: Ф0.1mm~Ф200mm

2. Detection speed:0.1~16m/s

3. Allowable relative speed of the sensor and wire rope:0 ~ 20m/s (online fixed installation)Allowable clearance between sensor guide sleeve and wire rope:0 ~15mm

4. The sensitivity of the detector should meet the stipulations in the following table: The unmeasurablearea should be less than 2% of the total length of wire rope.

The accuracy of qualitative detection is not less than 98%, and the accuracy of broken wirequantitative detection is not less than 90%.

Minor damage real-time detection rate: > 90%, slight damage quantitative judgment accuracy rate:> 95%

Constant damage real-time detection rate: > 95%, constant damage quantitative judgment accuracy rate:> 95%

Hazard damage real-time detection rate: > 100%, hazard damage quantitative judgment accuracy rate:> 95%

Limit damage real-time detection rate: > 100%, limit damage quantitative judgment accuracy rate: > 95%

5. Metal cross-sectional area quantitative change rate (LMA) detection capacity:

Detection sensitivity repeatability permissible error: ± 0.055%

Detection accuracy indication error: ± 0.5%

6. Position (L) detection capability: Detection length indication percentage error: ± 0.3%

Axial position accuracy of the injure point: 0.5mm Axial position relative error: 1mm/m

7. System operating voltage: AC127/220V±20% /50Hz

8. Dustproof and waterproof rating: IP54

9. Working environment temperature: -20℃～+60℃；

10. System power consumption: ≤1 kW

11. Local damage (LF) detection capacity: corrosion, broken wire (fracture gap ≥ 1mm), deformation and loose strands.