Mining Ropes Wire Rope Flaw Detector Cableway Elevator Wire Rope Flaw Detector Steel Rope Flaw Detector

Mining Ropes Wire Rope Flaw Detector Cableway Elevator Wire Rope Flaw Detector Steel Rope Flaw Detector

1. Specifications

Standards: GB/T21837-2008, ASTM E1571-2001 (Standard specification for electromagnetic examination of ferromagnetic steel wire rope), GB/T5972-2006/ISO 4309:90, GB8918—2006

Detecting range:Φ1.5—300 mm (choose different sensor)
Relative velocity between sensor and wire rope:0.0—6.0 m/s Best choice:0.3—1.5 m/s
Best gap between guide sleeve and wire rope: 2—6 mm,allowed gap:0—15mm

Output file type: Word files output

Alarm: Sound and light alarm
Broken wire rope location(LF)detection
Qualitative judgement accuracy: 99.99%
Quantitative assessment
Repeatability error of Sensitivity: ±0.055%
Display error: ±0.2％
Error of location detection,(L): ±0.2%
Power:5V computer power supply
WEIGHT OF SENSOR: < 10kg (Regular sensor)

Environment temp.-10℃~40℃

Air pressure:86~106Kpa

Relativity humidity:≤85%

The windows system of wire rope computer detector is the GB system renewal product which based on the DOS software theory and the real time display alarm guiding ideology utilizes Visual Basic6.0 the programming language foundation, carries on the compilation to become.

This system hardware part uses the domestic and foreign advanced magnetic sensor and the independent research and development sampling module unifies, through RS232 (or USB) main line driving, directly storage data in computer.

This system software part is in the wavelet transformation analysis foundation, in utilizing Visual Basic 6.0 programming language foundation, carries on the compilation to become. Achieve the functions such as data acquisition and control, data analysis, data display, data storage and so on. Increase the visible characteristic in the DOS software function, and by its unique tendency continuously to track the way, may continuously, the dynamic observed data signal and its the change situation, and the real time display obtained result and sends out the alarm; Software increased the automatic evaluation function; In the partial flaw demonstrated on increased cross section and the total sectional area percentage; Software and Windows are completely compatible, suits to user's inertia operation, uses the Word files form production examination report.

This system software may compatible wire rope computer detector DOS software sampling data format, and can analysis processing to it.

The windows system took an independent operating procedure and the safe examination system, can conveniently be suitable for each kind of modern computer, and completes a series of examinations procedure.

2. Systems Demand

2.1 Computers Hardware Disposition Demand:

Processor: Above Celeron 1.5GHZ
Memory: 128MB
Hard disk: 10G
Connection: RS232 or USB
Monitor: Above VGA

2.2 Software Environment Demand:

• This system supports the Windows XP, Windows 7, Linux etc operating system;

• Need install Microsoft office word platform.

2.3 System Disposition

3. Sensor introduction

Magnetic sensor: The sensor is composed by displacement locator (Leading wheel, encoder), the magnetization installation and the sampling organization. After the system activated, the wire rope and it has the relative movement, then it can gather the signal.

Displacement locator: Leading wheel rotated a circle, the photoelectric encoder sends out the sampling instruction pulse, realizing equal space sampling.

Magnetization installation: When the wire rope and it has the relative movement, completes to the wire rope axial magnetization.

Sampling organization: When the wire rope and the sensor have the relative movement, the Hall element composed the sampling channel will transform the wire rope magnetic flux leakage change condition into the simulation voltage signal.

4. HUATEC real-time alarm apparatus

The HUATEC real-time alarm apparatus is a portable multi-purpose data acquisition, through the RS232 transmission line to send and save the converted data signal to the computer, make use of the computer CPU formidable function on-line and real-time processing analysis, according to the equivalent threshold value which will set in advance sends out the real-time alarm. One group to give the sensor power supply lithium battery group, the output is 5V. There is an addition charge port to be possible to supply the charge and the power switch.

Picture 2 Signal Sampling Wiring Diagram

5. Software introduction

Picture 3 Main Functions Items

Picture 8 Parameter Settings

6. Broken wire analysis

Broken wire analysis (Ctrl+N) is the man-machine dialogue procedure, is the analysis processing function item for the test data. Two methods can enter this procedure: One is directly entering the human body dialogue according to preceding; Another is "open" way to enter, click on operating column "broken wire analysis" item (or click on tool column icon button) to enter the operating sequence, or click on “file" column "open" item, the inquiry window will pop, click on "analysis" item to enter the operating sequence.

Picture 11 Broken Wire Analysis Interface Picture

Broken wire analysis (man-machine dialogue) the surface introduction that:

• In the procedure window, center is the data wave form display picture, a screen altogether displays 16 lines, and each line altogether displays 512 sampling spots.
• Display window two sides numerals are both distance display: Left is this wave form corresponding testing starting location; Right is total this wave form corresponding testing displacement between the starting and ending location.
• Two page numbers under the display window: One is the total page number; the other is the current page number.
• There are several buttons in the middle of the two page numbers, when the total page number is not more than 1, there are two buttons, “Analyze automatic” and “Analyze artificial”, when the total page number is over 1, there will add one: “Next”. Click on “Analyze automatic”, the system will judge the red marked spot and calculate each partial flaw result according parameter that select (for example broken wire equivalent number or proportion of cross-sectional area to total cross-sectional area); Click on “Analyze artificial”, the system will mark all suspicious wave signal points, the points will be confirmed or removed by the experienced operator, the system will write up report according to judgment result. The two operations will only be aimed at the current page, must reselect operating mode after the page turning. “Next” mainly is used in turning the page, will only be able to turn one page to next page, the earlier pages will be not able to view before judging ending. Dragging the roll to scan the earlier pages will be allowed only after judging ending, but amending is not allowed.
• There a row display below the buttons, left side is the route and name of the file opened this time; the middle is the LMA0 value, this value is the reference value of cross-sectional areas automatically calculated by the system for this group of data, is on basis of the first row average of this data wave form. In calibrating process it just need to fill in cross-sectional area parameter column, the system will evaluate processing analyzing data the metallic cross-sectional area changing (for example deterioration) according the LMA0 value.
• When use artificial analysis, a group of VPP value appears in right and bottom, namely former crest to crest value and latter crest to crest value of this wave form partial abnormity signal in the location marked in red spot in display window. When use the automatic analysis, this value will not appear.

Broken wire analysis procedure as follows:

• Select a group of parameter to suit this evaluation, if there is no suitable one to be possible to add or amend, and confirm the selection to use.

• Enter the procedure according to the above operating procedure, a “Select data file” window will pop, and click on prepared analyzing processing data file, open to enter the procedure item.

Picture 12 Data Selection File Window

• The system will act according to the parameter logarithm which will elect according to carry on the automatic scan, when the partial flaw signal two crests values mean value will be bigger than first threshold value, will carry on the sign note to this place, and will give the sign note to this page all similar situations.
• Each point will be confirmed or removed by the experienced operator, and the slack strand, jumping wire, deformation and other flaws of the wire rope may be judged from the testing wave form. Pay attention to isosceles triangle whose two crests values the data difference is not big, and wave form crest is similar to acute angle. The concrete flaw characteristic and the evaluation detailed knowledge may be seen in the chapter 6, the flaws analysis and the evaluation.
• When the operator has no different opinion on the marked red spots in current page screen, and judge them broken wire, directly click on "Analyze automatic" button. All the marked red spots in this page will be confirmed for broken wire, the system will automatic calculate quantification value in each place, and display the value list in the result report. Click on "Next" button to turn page and operate again.
• When the operator has different opinion according to flaw signal on part of the marked red spots in current page screen, must reject the part, and will have to use artificial analysis evaluation procedure. Directly click on "Analyze automatic" button to enter the artificial analysis procedure. All red spot mark will be scanned one by one in the current page, when scanning to some a spot, the mark color will turn black, and its VPP will appear in right below, and a dialogue window will pop and inquire whether this mark is broken wire. If judge it broken wire, click on "Yes" in the window, and the marked spot will assume red; If it is not, reject it, then click on "No", the marked spot will assume yellow. Also may use the fast key to judge that, if confirm, press "Y" (or press the “Enter” key), if deny, press "N". When need continuously confirmation or denying, long press "Y" (press the “Enter” key) or "N" continuously similarly judge.
• When the operator has different opinion according to flaw signal on all the marked red spots in current page screen, all will give them all denying, long press "N" key. When this group of data have the multi- pages screen, may directly click on the next page to give the full page denying and to enter the next page of screen, so all the marked in this page will be denied, and no longer enter in the judging result, but last the page cannot so, only be able to long press "Y" or "N" according to the above method.
• After each page analysis ending, two buttons assume excessiveness.
• If the result report needs to be analyzed and evaluated this time, must when the analysis evaluation ends, immediately enter report column and click “broken wire report” item, open and view the result report.

• After assigning out data file, may continue to reselect data file that need analysis.

7. Deterioration analysis

The deterioration analysis (Ctrl+L) is evaluation procedure to the testing wire rope metallic cross-sectional area change (for example deterioration), is an automatic evaluation function item for the test data according to a datum value. Click on “Deterioration analysis” in operating column (or direct use fast key) to enter the operation sequence (As Picture 13).

Picture 13 Deterioration Analysis Interface Picture

Deterioration analysis interface introduction:

• When enter the procedure, a “deterioration warning threshold” window will pop (like Picture 14), input a positive number in the blank space according to each profession standard specification limiting value, or according to one’s own requirement. The procedure will rest on this value will calibrate the result according to metallic cross-sectional area reduce (for example deterioration). When the result surpasses this value, color of deterioration percentage in right surface will turn red. The wave form data result that assumes red will be recorded in the deterioration report.

Picture 14 Data Selection File Window

• In the procedure window, center is the data wave form display picture, a screen altogether displays 16 lines, and each line altogether displays 512 sampling spots.
• Display window two sides numerals are both distance display: Left is this wave form corresponding testing starting location; Right is the increasing or decreasing percentage of this wave form corresponding the metallic cross-sectional area datum value, namely LMA change percentage.
• There are several buttons in the middle of the two page numbers, when the total page number is not more than 1, there are two buttons, “Print current page” and “Printing OK”, when the total page number is over 1, there will add two: “Back” and “Next”. “Print current page” is that, regarding the current page graph, click on "the printing current page" button, regarding each current page in requirement, may click on this button; “Enter” is the button to confirm to print the page in requirement. Each A4 paper may print two screens, may print all the pages in waiting in turns. When just one screen need to be printed, may click on “Print current page” first, and click on “Enter”, the current page will be printed immediately. “Back” and “Next” is the function buttons that used in turning page.
• There a row display below the buttons, left side is the route and name of the file opened this time; in the middle it displays the cross-sectional area datum value, the system will evaluate processing analyzing data the metallic cross-sectional area changing (for example deterioration) according this value.

Deterioration analysis concrete sequence of operation as follows:

• Click on "Deterioration analysis" in operating column, "deterioration warning threshold" window will pop, according to one own requirement or each profession standard, input with a value in the blank space, and confirm.

• After inputting the parameter, a primary data folder will pop. Select the file that needs to be analyzed and open it.

• The surface will display this file data wave form, and display each position section corresponding metallic cross-sectional area changing. If the metallic cross-sectional area changing surpasses the supposing value, the number in right surface turn red reports to warn, this section corresponding wave form spot position, the conclusion position and the greatest value of this section reduction will be recorded in the report.

• Regarding each current page in requirement, may click on “Print current page”,When all the pages in requirement are selected, click on “Printing OK” and enter the printing procedure.

Attention: When click on the printing, in advance connect the printer and the computer, and set the printer which connects as default printer.

8. Sensor option

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