Steel-Wire Rope Online Automatic Inspection System
.Real-time inspection on safety status of Steel-cord Conveyor Belt
Reliably preventing accidents from breakage of Steel-cord Conveyor Belt
Scientifically reducing cost of steel core conveyor belt
Effectively improving productivity of steel core conveyor belt
Steel-wire rope, as a "high risk" component of important equipment in hoisting and conveying, is always regarded as "lifeline" in these fields, and also as a difficulty or even a "blind point" in equipment management because of no reliable inspection system. The wire rope safety operation can only be supported by simple visual inspection or periodical replacement of wire rope.
Visual inspection can only observe limited surface flaws, unable to detect hidden dangers like internal wire breakage, corrosion, abrasion and especially fatigue. Periodical replacement of wire rope causes huge waste and increase of production cost. Energy consumption used for wire rope inspection every year is also a big waste. Even so, safe application of wire rope can still not be guaranteed. Many wire breakage accidents just happened before periodical replacement; some new ropes even break off within very short time. According to statistics of State Administration of Safety Production Supervision, there are more than 1065 accidents in Chinese coal mine industry in the past two years, half of which is caused by wire breakage. The most serious accident caused 14 dead and 5 seriously wounded. Wire breakage accident occurred to transportation equipments is also very serious in other industries, such as port, oil, construction, steel, metallurgy, water conservancy, and electric power.
Our Steel-Wire Rope On-line Automatic Inspection System will thoroughly change the status. The system can not only conduct real-time inspection on all wire rope flaws and timely evaluation on residual bearing capacity and service life of wire rope, but thoroughly eliminate hidden dangers, scientifically reduce wire rope cost, and effectively improve productivity. This inspection system adopts wired or wireless data transmission way, inspection device with high sensitivity, collecting large capacity data device and multi-channel main controlling center once are installed on a appropriate place, and can omni-directional on line automatic monitor wire rope. The system consists of Weak Magnetic Loading Device, Module Combination Inspection System, Stable Running Holding Device, Data Collecting-conversion-processing-storing Device, Command Control Receiving-dispatching Network Terminal, Information Processing Communication System and Multi-channel Command Controlling Workstation.
Single-rope winding Hoisting machine
Shaft Tower Six-rope Friction Hoist
Ground Four-rope Friction Hoist
Shaft Tower four-rope Friction Hoist
Diagram
Multi-channel Command Controlling Workstation
Data Collecting-conversion-processing-storing Device
Wired Communication and Transmission System
Weak Magnetic Loading Device
Module Combination Inspection System
Guide wheels
Wire Rop
Features
This inspection system is a fixed installing system based on the modern network technique. It is a kind of real time on-line automatic wire rope quantitative inspection system with features of high efficiency, high-speed, reliability, maintenance-free and convenience.
High detection sensitivity and accuracy for wire rope external & internal defects;
Handy installation: high-sensitivity sensor, large-capacity data acquisition device and other auxiliary facilities are installed once in respective proper position, with high precision and strong practicability;
Convenient maintenance: characterized by multi-point fixed installation, high durability, long-term free of maintenance, wired or wireless data transmission channel, low investment, quick starting, handy operation and maintenance, low operation cost;
High reliability and easy management: the whole system not only can provide reliable information for reference when making decisions for users but also can provide an analysis tool for experts; it is the most advanced and accurate on-line non-destructive and quantitative wire rope (cable) inspection and network monitoring system at present in the whole world;
Strong targeted: The elastic mechanism and sliding translational follower device are designed to settle the situation --- like jumping and shaking to a different extent or limited translational movement existing in running of wire rope used in hoisting equipment -- to ensure accurate, stable and reliable monitoring result;
Strong adaptability: full considerations are given to user environment such as temperature, humidity, strong wind and other physical environmental factors in original design, and various weathering performance and type tests have been completed in research experiment;
Strong compatibility: it can be easily incorporated and compatible with existing multifunction control system established in major equipment and important facilities used in each industry.
Performance
Inspection sensitivity: < 5V/G
Adjustable sensitivity value: 2.6V/G
Inspection accuracy: < 0.05%
Actual inspection uncertainty on LMA: < 0.5%
Inspection speed: < 30M/S
Working speed: 0.2-13M/S
Axial Indication value precision: 5 X 10-4M
Proofreading error in inspection length: < 10mm/100M
Normal flaw value real-time accuracy rate: > 95%
Damaging flaw value real-time accuracy rate: > 98%
Limiting flaw value real-time accuracy rate: 100%
Normal flaw value quantitative accuracy rate: > 90%
Damaging flaw value quantitative accuracy rate: > 95%
Limiting flaw value quantitative accuracy rate: > 98%
Structure
1) Combined Inspection System
On-line fixed installation suitable for all-weather
Waterproof, quakeproof, greasy-dirt-proof and wide working temperature -35℃ ~ +65℃
No need daily maintenance
Single or double test point for each rope available.
Remote commander control, real time continuous inspection in both moving directionon
On-line collection of various flaws informations, including fatigue.
2) Multi-function Data Collection and Conversion Workstation
Intelligent, multi-channal, duoble-direction, automatic converting and transmitting system
Modularized unit, combined configuration
Anti-interference protection
ouble-assurance device with Yellow lighting pre-alarm indication and red lighting alarm for emergency.
3) Sound-light Alarm System
On-scene sound-light alarm device
Green/yellow/red indicator for different level of rope safety status
Manual and automatic setup for machine control.
Safety braking (stop) when upper limit exceeds (red light)
4) TCK Terminal Command Controlling Center
Automatic or manual alarm cancel set up.
Wired or wireless transmission
Network compatible and alarm extensibl
Windows + TCK dedicated data management software
Center processing system, responsible for inspection data daily analyses
Real-time review or print flaws data analyze report, evaluation on residual capacity bearing and service life of inspected wire rope.
Inspection system
Data collection & conversion workstation
Audio-visual alarm system
Command controlling centre
Combined Inspection System
First, install and fix the Combined Inspection System to testing points which should be mostly concerned and monitored, to realize the automatic testing during normal working procedure of wire rope. Its basic action is:
1. Weak magnetic loader, make original rope magnetic field to be in order and get ready for detecting.
2. High performance sensor component, collecting defect data and output original signal.
Regarding the vibration and horizontal movement of wire rope in different hoisting machine, our system also equips with Flexible Follower Device or Stabilizer mechanism to ensure the wire rope passing through sensor head smoothly.
Multi-function Data Collection and Conversion Workstation
Multi-function Data Collection and Conversion Workstation receive original test information, accomplish data conversion, preliminary data processing and storage, real time output defect signal to control center via wired or wireless communication.
Audio-visual alarm system
Sound-light Alarm System gives alarm according to the result of Multi-function Data Collection and Conversion Workstation. According to the regulation of "Wire Rope On-Line Non-Destructive and Quantitative Inspection Method and Determinant Rule" issued by National Development and Reform Commission, make judgment to wire rope safety status.
Terminal Command Controlling Center
Terminal Command Controlling Center, the nerve center of the whole monitoring system, consists of Center Processing module, Computer Hardware and Software, Network Communication System and Display terminal. Its function is to made a comprehensive analysis to testing information collected by Multi-functional Data Collection and Conversion Workstation and give daily analyses result and deterioration trend of wire rope defects. User may search the current defect information or at any past moment information, including defect status, value, position, type, curve and deterioration trend. Testing result is available at any time through terminal display or printing.
In order to guarantee the system stable operation, Terminal Command Controlling Center adopts multi-Channel information synchronized.
Exchange and backup. Command control, self-diagnose, system coordinate and start/terminate can be done in the same time; Real time Programming, support multi-choice analyses/management, double-channel information exchange (realizing the connection and share between interior and exterior network).
