scholarly journals Design of Tunnel Magnetoresistive-Based Circular MFL Sensor Array for the Detection of Flaws in Steel Wire Rope

2016 ◽  
Vol 2016 ◽  
pp. 1-8 ◽  
Author(s):  
Liu Xiucheng ◽  
Wang Yujue ◽  
Wu Bin ◽  
Gao Zhen ◽  
He Cunfu
Keyword(s):  
Magnetic Field ◽  
Sensor Array ◽  
Steel Wire ◽  
Flaw Detection ◽  
Sensor Arrays ◽  
Wire Rope ◽  
Mutual Correlation ◽  
Wire Ropes ◽  
Technical Requirements ◽  
Lift Off

Tunnel magnetoresistive (TMR) devices have superior performances in weak magnetic field detection. In this study, TMR devices were first employed to form a circular magnetic flux leakage (MFL) sensor for slight wire rope flaw detection. Two versions of this tailor-made circular TMR-based sensor array were presented for the inspection of wire ropes with the diameters of 14 mm and 40 mm, respectively. Helmholtz-like coils or a ferrite magnet-based magnetizer was selected to provide the proper magnetic field, in order to meet the technical requirements of the TMR devices. The coefficient of variance in the flaw detection performance of the sensor array elements was experimentally estimated at 4.05%. Both versions of the MFL sensor array were able to detect multiple single-broken wire flaws in the wire ropes. The accurate axial and circumferential positions of these broken wire flaws were estimated from the MFL scanning image results. In addition, the proposed TMR-based sensor array was applied to detect the MFL signal induced by slight surface wear defects. A mutual correlation analysis method was used to distinguish the signals caused by the lift-off fluctuation from the MFL scanning image results. The MFL sensor arrays presented in this study provide inspiration for the designing of tailor-made TMR-based circular sensor arrays for cylindrical ferromagnetic structural inspections.

scholarly journals A Sensor for Broken Wire Detection of Steel Wire Ropes Based on the Magnetic Concentrating Principle

Sensors ◽  
2019 ◽  
Vol 19 (17) ◽  
pp. 3763 ◽  
Author(s):  
Zhang ◽  
Jing ◽  
Xu ◽  
Zhan ◽  
Tan
Keyword(s):  
Permanent Magnet ◽  
Structural Parameters ◽  
Steel Wire ◽  
Sensor Arrays ◽  
Wire Rope ◽  
Hall Sensor ◽  
Wire Ropes ◽  
Depth Analysis ◽  
The Wire ◽  
Lift Off

Electromagnetic testing is the most widely used technique for the inspection of steel wire ropes. As one of the electromagnetic detecting approaches, the magnetic flux leakage (MFL) method has the best effect for the detection of broken wires. However, existing sensors based on MFL method still have some problems. (1) The size of the permanent magnet exciter is usually designed according to experience or rough calculation, and there is not enough depth analysis for its excitation performance; (2) Since the detectable angular range for a single Hall component is limited, Hall sensor arrays are often employed in the design of MFL sensors, which will increase the complexity of the subsequent signal processing due to the extensive use of Hall components; (3) Although the new magneto-resistance sensor has higher sensitivity, it is difficult to be applied in practice because of the requirement of the micron-level lift-off. To solve these problems, a sensor for the detection of broken wires of steel wire ropes based on the principle of magnetic concentration is developed. A circumferential multi-circuit permanent magnet exciter (CMPME) is employed to magnetize the wire rope to saturation. The traditional Hall sensor array is replaced by a magnetic concentrator to collect MFL. The structural parameters of the CMPME are optimized and the performance of the magnetic concentrator is analyzed by the finite element method. Finally, the effectiveness of the designed sensor is verified by wire breaking experiment. 1–5 external broken wires, handcrafted on the wire rope with a diameter of 24 mm, can be clearly identified, which shows great potential for the inspection of steel wire ropes.

scholarly journals The use of a magnetic flux leakage in the assessment of the technical state of a steel wire rope subjected to bending

2018 ◽  
Vol 48 (1) ◽  
pp. 493-513
Author(s):  
Paweł Mazurek ◽  
Jerzy Kwaśniewski ◽  
Maciej Roskosz ◽  
Ryszard Siwoń-Olszewski
Keyword(s):  
Magnetic Field ◽  
Steel Wire ◽  
Wire Rope ◽  
Technical State ◽  
Magnetic Flux Leakage ◽  
Wire Ropes ◽  
State Of Stress ◽  
Real Objects ◽  
The Relationship ◽  
Flux Leakage

Abstract The technical state of steel wire ropes has a decisive impact on the safety of people using the equipment in which they are installed. The basis for increasing safety is the ability to assess the condition of the working steel wire. The article presents the use of magnetometric sensors to determine the relationship between the number of steel wire rope bends and its magnetic field induction value. This knowledge, referred to ropes working on real objects, allows to determine the state of stress prevailing in them as well as their condition.

Study of Accumulated Defects of Steel Wire Ropes

2011 ◽  
Vol 177 ◽  
pp. 159-167 ◽  
Author(s):  
Michal Lesňák ◽  
Jaroslav Foukal ◽  
Lukáš Slivečka ◽  
Jana Trojková
Keyword(s):  
Magnetic Field ◽  
Field Distribution ◽  
Radial Direction ◽  
Surface Defects ◽  
Steel Wire ◽  
Wire Rope ◽  
Magnetic Field Distribution ◽  
Cylinder Axis ◽  
Wire Ropes ◽  
The Face

The article deals with the accumulated defect impact on magnetic field distribution around a magnetized rope. A study of such effects was made on a cylinder-shaped model of steel wire rope with a diameter of 40 mm, in which individual wires with a diameter of 1 mm are parallel to the cylinder axis. Defects are wire breaks with the face distance of 1 mm. An analysis was made of the accumulated defect responses in a rope in one radial direction at various distances from the rope axis, then in two different radial directions, and surface defects in the direction of the rope.

The Analysis of Wire Rope Tension Sensor Elastic Body Based on Solidworks

2012 ◽  
Vol 591-593 ◽  
pp. 1603-1606 ◽  
Author(s):  
Peng Liu ◽  
Xin Zhang ◽  
Ya Kun Huang ◽  
Ji Xu Rong
Keyword(s):  
Elastic Body ◽  
Steel Wire ◽  
Strain Sensor ◽  
Wire Rope ◽  
Reliable Data ◽  
Inspection System ◽  
Software Modeling ◽  
Modeling And Analysis ◽  
Wire Ropes ◽  
Tension Sensor

This article introduces unbalance phenomenon when several steel wire ropes hoist skip and some main methods of measuring steel wire ropes tension in coal mine. Use the strain effects to design a sensor which can be used to measure the tension of steel wire rope, to provide reliable data for the subsequent online tension inspection system. In order to facilitate the sensor in this system, the height of the sensor needs to be low enough. As one of the most important parts of the strain sensor, the elastic body is also low-height. To solve that problem, first using the SolidWorks software modeling and analysis of elastic body to design the sizes and obtain the best patch position of strain gauge.

scholarly journals Convolutional Autoencoder-Based Flaw Detection for Steel Wire Ropes

Sensors ◽  
2020 ◽  
Vol 20 (22) ◽  
pp. 6612
Author(s):  
Guoyong Zhang ◽  
Zhaohui Tang ◽  
Jin Zhang ◽  
Weihua Gui
Keyword(s):  
Steel Wire ◽  
Flaw Detection ◽  
Feature Learning ◽  
Surface Damage ◽  
Training Data ◽  
Lubricating Oil ◽  
Damage State ◽  
Wire Ropes ◽  
Discriminative Feature ◽  
Fault Recognition

Visual perception-based methods are a promising means of capturing the surface damage state of wire ropes and hence provide a potential way to monitor the condition of wire ropes. Previous methods mainly concentrated on the handcrafted feature-based flaw representation, and a classifier was constructed to realize fault recognition. However, appearances of outdoor wire ropes are seriously affected by noises like lubricating oil, dust, and light. In addition, in real applications, it is difficult to prepare a sufficient amount of flaw data to train a fault classifier. In the context of these issues, this study proposes a new flaw detection method based on the convolutional denoising autoencoder (CDAE) and Isolation Forest (iForest). CDAE is first trained by using an image reconstruction loss. Then, it is finetuned to minimize a cost function that penalizes the iForest-based flaw score difference between normal data and flaw data. Real hauling rope images of mine cableways were used to test the effectiveness and advantages of the newly developed method. Comparisons of various methods showed the CDAE-iForest method performed better in discriminative feature learning and flaw isolation with a small amount of flaw training data.

A Wire Contact in the Construction of a Steel Rope

2014 ◽  
Vol 683 ◽  
pp. 3-8
Author(s):  
Jozef Krešák ◽  
Pavel Peterka ◽  
Stanislav Kropuch ◽  
Andrea Bérešová
Keyword(s):  
Steel Wire ◽  
Transportation Systems ◽  
Wire Rope ◽  
Factors Affecting ◽  
Wire Ropes ◽  
Construction Design ◽  
Deformation Properties ◽  
Labor Safety ◽  
Mining Coal ◽  
Corrosive Environments

A rope is an important, highly effective and one of the oldest transportation systems used in transport by mankind. Nowadays, steel ropes are mainly used for moving loads in mining - coal and ore exploitation, vertical or horizontal transport of persons and goods by cranes, elevators, lifts and cable ways. In many cases steel wire ropes are employed in extreme conditions with respect to the load of the rope: high temperature plants, mining corrosive environments and etc. In terms of labor safety it is necessary to certify each rope people come in contact when working with loads or a rope is used for transportation. It has to be done earlier than a rope is put into operation or on the market. Despite the fact the tests were performed correctly, a rope may not achieve the desired rope life. The great impact on the life of a wire rope has its interaction with a device a rope is deployed on. Interaction of a steel wire rope with a device it is deployed on has a great impact on its life. Durability is also affected by the way a rope is loaded, its maintenance and regular re-examination as well as its construction. Design accuracy is assessed according to strength and deformation properties of wires a rope is made of and a rope cross-section construction is taken in account as well. The important aspect of steel wire rope durability (which can be mostly influenced by a manufacturer) is an appropriate design of diameters and angles of wires winding in accordance with exactly defined conditions of operation. The paper presents models of ropes equally loaded which eliminates the most unfavorable factors affecting their life cycle.

The influence of rotation speed on the bending fatigue lifetime of steel wire ropes

2010 ◽  
Vol 225 (3) ◽  
pp. 520-525 ◽  
Author(s):  
Y A Onur ◽  
C E İmrak
Keyword(s):  
Rotation Speed ◽  
Steel Wire ◽  
Experimental Tests ◽  
Wire Rope ◽  
Experimental Investigations ◽  
Thermal Camera ◽  
Fatigue Lifetime ◽  
Bending Fatigue ◽  
Wire Ropes ◽  
Different Diameters

This article presents experimental investigations to determine the influence of rotation speed on the bending fatigue lifetime of rotation-resistant rope and non-rotation-resistant rope. Heat generated by the rotation speed on steel wire rope samples has been measured by a thermal camera. Two sheaves with different diameters have been used to obtain the effect of sheave diameters on the heat alterations and bending fatigue lifetime. Two experimental tests have been conducted to determine the effect of insufficient lubrication on the bending fatigue lifetime. The results indicate that rotation speed affects the steel wire rope lifetime subjected to bending fatigue.

Study of Steel Wire Ropes Defects

2014 ◽  
Vol 683 ◽  
pp. 55-60 ◽  
Author(s):  
Michal Lesňák ◽  
Jan Procházka ◽  
Ivo Hlavatý ◽  
Jaromír Pištora ◽  
Gabriela Kostiuková
Keyword(s):  
Finite Element ◽  
Magnetic Fields ◽  
Magnetic Induction ◽  
Steel Wire ◽  
Wire Rope ◽  
Finite Element Program ◽  
Wire Ropes ◽  
Element Program

This article deals with the study of defects in steel wire. In the study we model magnetic fields around rope genetated by magnetized part of rope. The work is based on the finite element program ANSYS. For the purposes of the experiments we consider one strand wire rope construction. We define different kinds of defects and faults. The shape of the magnetic induction lines of generated fields depends on the size of the defect, the depth of rope violation or the presence of other nearby defects. The location and number of disturbances have been chosen to achieve the most versatile outputs. All of these modifications were analyzed and the results displayed in the 3D colored.

scholarly journals Signal Space Separation Method for a Biomagnetic Sensor Array Arranged on a Flat Plane for Magnetocardiographic Applications: A Computer Simulation Study

2018 ◽  
Vol 2018 ◽  
pp. 1-19 ◽  
Author(s):  
Kensuke Sekihara
Keyword(s):  
Magnetic Field ◽  
Sensor Array ◽  
Sensor Arrays ◽  
Signal Space ◽  
Signal Space Separation ◽  
Vector Sensor ◽  
Vector Sensors ◽  
Modified Sensor ◽  
Space Separation ◽  
The Magnetic Field

Although the signal space separation (SSS) method can successfully suppress interference/artifacts overlapped onto magnetoencephalography (MEG) signals, the method is considered inapplicable to data from nonhelmet-type sensor arrays, such as the flat sensor arrays typically used in magnetocardiographic (MCG) applications. This paper shows that the SSS method is still effective for data measured from a (nonhelmet-type) array of sensors arranged on a flat plane. By using computer simulations, it is shown that the optimum location of the origin can be determined by assessing the dependence of signal and noise gains of the SSS extractor on the origin location. The optimum values of the parameters LC and LD, which, respectively, indicate the truncation values of the multipole-order ℓ of the internal and external subspaces, are also determined by evaluating dependences of the signal, noise, and interference gains (i.e., the shield factor) on these parameters. The shield factor exceeds 104 for interferences originating from fairly distant sources. However, the shield factor drops to approximately 100 when calibration errors of 0.1% exist and to 30 when calibration errors of 1% exist. The shielding capability can be significantly improved using vector sensors, which measure the x, y, and z components of the magnetic field. With 1% calibration errors, a vector sensor array still maintains a shield factor of approximately 500. It is found that the SSS application to data from flat sensor arrays causes a distortion in the signal magnetic field, but it is shown that the distortion can be corrected by using an SSS-modified sensor lead field in the voxel space analysis.

Determination of Elastic Modulus of Steel Wire Ropes for Computer Simulation

2014 ◽  
Vol 683 ◽  
pp. 22-27 ◽  
Author(s):  
Ján Boroška ◽  
Alena Pauliková ◽  
Vladimír Ivančo
Keyword(s):  
Computer Simulation ◽  
Elastic Modulus ◽  
Influencing Factors ◽  
Modulus Of Elasticity ◽  
Steel Wire ◽  
Wire Rope ◽  
Wire Ropes ◽  
Real Value ◽  
Construction Type

Modulus of elasticity of steel wire rope (elastic modulus) is a characteristic value, which is important not only for users of the steel rope, but also for designers of machines and machinery that are equipped with the steel wire rope. Values of the elastic modulus depends predominately on the elastic modulus of the material, which the rope is manufactured from as well as it depends on the various other factors. The most important influencing factors are as follows: rope construction, type of core, angle and way of wire stranding, angle and way of rope lay as well as kind of lubricant. The real value of the elastic modulus has also impact on prolongation of the steel wire rope and on intensity of its dynamical loading. The rope elastic modulus value can be determined by means of the various methods. There are analysed in this article such methods for determination of the rope elastic modulus, which can be applied for a computer simulation.

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