Research For On-line Measuring Device Of Broken Wire Rope

As the traction and bearing component, wire rope has light weight, good elasticity and will play an important role in all walks of life. However, the complex structure and harsh environment make the wire rope occur broken, corrosion, abrasion and other faults. These faults will be a danger to the operator and device if we do not discover them in time. Broken wire is one of the most common and most difficult to forecast in these faults. In present, people still use original eye-measurement method and replace wire rope regularly in the field of wire rope inspection, these methods not only get inaccurate result but also cause serious waste of the resources. So, an intelligent measuring instrument for the broken wire must be made no delay.Based on the deep research on the domestic and international research for broken wire rope inspection, we find that magnetic flux leakage testing method which checks the broken wire rope by means of magnetic flux leakage is more often used. However, this method exist flaws in weak magnetic flux leakage recognition because of broken wire coming from interior. This paper is designed a new broken wires testing sensor-a solenoid-monitoring sensor detecting broken wire. This article studies the main content is as follows:First, the author analyzes the development of wire rope at home and abroad, then give a detail describe to the several common failures and the out-of-service standards of wire rope. Meantime, the merits and demerits of the present broken wire rope testing method are analyzed and a new principle for testing method is presented in the paper.Secondly, this paper mainly researches the testing principle about the new broken wires testing sensor-a solenoid-monitoring sensor detecting broken wire. There are three coils on magnetic inert tube, the primary coils on either side of tube, which are droved by multifunctional AC power source, are linked backward, the central secondary coil is linked with system processing circuit. The magnetic field of central secondary coil weakens, almost vanishes because the magnetic field of primary coils is opposite. When the wire rope occur broken wire, magnetic permeability is precipitous decline and the central secondary coil lose balance, then it produce voltages. We can get the information broken wires according to voltages. The model of sensor is established in accordance with the above-mentioned principle. In the paper, we also study the number in the coil that surrounds it, the size and the window area.Thirdly, on the basis of the new sensor has been developed, we uses MSP430F149 single-chip as center control unit and design single sampling module, communication module with PC and distance testing module which judged the position of broken-wire by recording the number of pulses. Also, the components used by module mentioned above are introduced in detail. Meantime, the software is designed about these modules. We achieved the aim of signal acquisition, processing, transmission and data storage.At last, In order to validate the feasibility of on-line measuring device of broken wire rope, the experiment platform is set up in the laboratory and a lot of experiments have been done on it. The results of experiment show that the new broken wires testing device has easy operation and high sensibility. So, the device has important practical significance and broad marketing promotion value.