Method And System Realization Of Broken Wire Of Steel Wire Rope Based On Magnetic Flux Leakage Detection

Steel wire ropes are widely used in key parts of large-scale machinery components,and the assessment of their health status is extremely important to ensure the safe and healthy operation of the entire machinery.As the service life increases,various damages will occur to the wire rope,and serious accidents may occur if it is not replaced in time.Therefore,studying the health status of steel wire ropes has great engineering value and academic significance for ensuring the smooth and safe operation of equipment and preventing the occurrence of major accidents.Since most of the wire ropes are made of high-carbon steel with good magnetic permeability,the electromagnetic nondestructive testing method has become the first choice for flaw detection.On the basis of literature research and analysis,this article focuses on the most common and most harmful wire rope broken wire defects as the research object,and adopts the method of magnetic flux leakage detection to detect the wire rope broken wire defects.Researches were carried out from three aspects: wire rope magnetic flux leakage signal form,wire rope magnetic flux leakage signal processing algorithm and wire rope magnetic flux leakage detection system,aiming to improve the accuracy of wire rope broken wire detection.The main research contents and innovations of this article are as follows:(1)In view of the fact that most of the existing literatures simulate and analyze the wire rope broken wire position,the width of the broken wire and the number of broken wires.This paper uses the finite element analysis software ANSYS to systematically simulate the shape of the wire rope magnetic flux leakage signal.The magnetic flux leakage signal mainly contains three components,which are: broken wire signal,strand wave signal and shaking signal.It is concluded that the shape of the broken wire signal is a shock signal,the shape of the strand wave signal is a sinusoidal signal,and the shape of a shaking signal is a jump signal that changes with the lift-off value.The validity of the simulation model is verified through experiments,and it provides a basis for the steel wire rope magnetic flux leakage signal processing.(2)In view of the high false alarm rate caused by the single-channel signal processing in the existing steel wire rope magnetic flux leakage signal processing methods,this paper uses multi-channel signal fusion to preprocess the steel wire magnetic flux leakage signal to enhance the signal-to-noise ratio of the original signal.After preprocessing,in view of the different characteristics of the three main magnetic flux leakage signals after imaging,a line detection method is proposed to filter out the wave noise.The experimental results show that,compared with the traditional method of eliminating strand noise,the method adopted in this paper has a better removing noising effect on the strand signal.After a large number of experimental demonstrations,the validity and reliability of the proposed method are verified.(3)In order to apply the algorithm proposed in(2)to practice,this paper builds a set of wire rope non-destructive testing system.It includes a hardware platform and a software platform.The hardware platform includes an excitation mechanism,a signal detection device,and a signal acquisition device;the software platform includes a parameter setting module,a visualization module,and so on.Finally,in order to verify the effectiveness of the wire rope non-destructive testing system,a test device was built,and a large number of repeated experiments verified the effectiveness and reliability of the system.