钢丝绳在线自动监测系统

Online automatic monitoring system for steel wire ropes

2020 年，微特技术有限公司（以下简称微特技术）正式被认定为国家重点专精特新小巨人企业。微特技术用 20 年时间，从一个小微企业，成长为国内大型起重机安全解决方案的首选品牌。“专精特新”四个字凝结着微特人追求产业之专、品质之精、创新之特的不懈努力。20 年来，微特技术笃定信念，始终专注于起重设备安全管理领域的研究，不断引领行业向起重设备故障诊断、大数据管理、全生命周期监测服务、智能化吊装生态系统方向发展，为推动国内起重安全管理领域的发展做出了贡献。

长期以来，钢丝绳的使用和管理始终是各企业设备管理的难点，因钢丝绳断裂造成的事故屡见不鲜，而每一次事故都伴随着财产损失和人员伤亡等严重后果。目前，肉眼看、卡尺量等依然是普遍使用的钢丝绳检测手段，检测技术与用户的安全管理需求之间存在着巨大的鸿沟。微特技术推出的钢丝绳在线自动监测（Wire Rope NonDestructive Testing，WRNDT）系统拥有高效、精准、便捷、安全等特点，较好地解决了目前钢丝绳检测中的难题。

WRNDT 钢丝绳在线检测系统是以国际标准铁磁性理论原理为基础，运用电磁检测技术，为实现无人值守实时非接触在线监测而专业打造的产品。可在线实时、高速自动采集钢丝绳断丝、疲劳、锈蚀、磨损等损伤信息，并通过算法对采集的大数据进行分析处理，形成钢丝绳损伤处损伤程度、伤点准确定位、电磁波形曲线等检测报告，实现钢丝绳缺陷检测的定量化进而可视化。WRNDT 系统体积更小、功耗更低、安装使用更加方便，不仅在起重机中使用，且在电梯、索道、桥梁悬索等领域也有着广阔的市场。

WRNDT钢丝绳在线检测系统的核心设备是微特技术全新一代钢丝绳探伤仪，该探伤仪是以自主知识产权、自主商业化生产的磁传感器为核心，以国际标准磁记忆探伤原理为基础专业打造的产品。其PT量级灵敏度与目前市面上MT量级灵敏度的钢丝绳探伤仪相比，提高上百万倍，对于Φ5～Φ50mm各种规格的钢丝绳，可快速检测出1根断丝，甚至敲击痕迹亦可轻松识别，且不需要使用励磁装置，从而避免了长时间使用过程中由于吸附金属粉末和碎屑导致的性能下降。

金属磁记忆效应是指：铁磁性金属材料在加工和运行时，由于受载荷和地磁场共同作用，在应力和变形集中区域会发生具有磁致伸缩性质的磁畴组织定向和不可逆的重新取向，这种磁状态的不可逆变化在工作载荷消除后不仅会保留，且与最大作用应力有关。金属构件表面的这种磁状态记忆着微观缺陷或应力集中的位置，即为磁记忆效应。当处于地磁场环境中的铁磁性构件受到外部载荷作用时，在应力集中区域会产生具有磁致伸缩性质的磁畴组织定向和不可逆的重新取向，该部位会出现磁畴的固定节点，产生磁极，形成退磁场，从而使该部位铁磁金属的导磁率最小，在金属表面形成漏磁场。该漏磁场强度的切向分量 Hpx 具有最大值，而法向分量 Hpy 改变符号并具有零值。这种磁状态的不可逆变化在工作载荷消除后依然保留记忆下来。

WRNDT 系统是基于金属磁记忆效应的基本原理制作的检测仪器，通过记录垂直于金属构件表面的磁场强度分量沿某一方向的分布情况，可对构件的应力集中程度以及是否存在微观缺陷进行评价，能对铁磁性金属构件内部的应力集中区，即微观缺陷和早期失效及损伤等进行诊断，防止突发性的疲劳损伤。

Boutique Zhonglian 35H, May 20th National Day, with a counterweight of 8 tons, an arm length of 44 meters, 1000 hours, and 7000 kilometers. The vehicle is exempt from inspection to ensure no accidents, and has complete procedures for insurance review. By May next year, the full price of the car will be sold for 680000 packages and upgraded.

In 2020, Weite Technology Co., Ltd. (hereinafter referred to as Weite Technology) was officially recognized as a national key specialized new small giant enterprise. In 20 years, Weite Technology has grown from a small and micro enterprise to the preferred brand for safety solutions for large cranes in China. The four words "specialized, refined, and innovative" embody the unremitting efforts of Weite people in pursuing industry specialization, quality excellence, and innovation. Over the past 20 years, Weite Technology has firmly believed, always focused on the research in the field of safety management of lifting equipment, and constantly led the industry to develop in the direction of fault diagnosis of lifting equipment, Big data management, whole life cycle monitoring services, and intelligent lifting ecosystem, making contributions to promoting the development of domestic lifting safety management

For a long time, the use and management of steel wire ropes have always been a difficulty in equipment management for various enterprises. Accidents caused by wire rope breakage are not uncommon, and each accident is accompanied by serious consequences such as property damage and casualties. At present, visual inspection and caliper measurement are still commonly used wire rope inspection methods, and there is a huge gap between inspection technology and users' safety management needs. The Wire Rope Non Destructive Testing (WRNDT) system launched by Micro Tech has the characteristics of high efficiency, accuracy, convenience, and safety, effectively solving the current challenges in wire rope testing

The WRNDT steel wire rope online detection system is a professional product based on the international standard ferromagnetic theory, using electromagnetic detection technology to achieve unmanned real-time non-contact online monitoring. It can automatically collect the damage information of wire rope, such as broken wire, fatigue, corrosion, wear, etc. online, in real time and at high speed, and analyze and process the collected Big data through algorithms to form the detection reports of the damage degree, accurate location of the damage point, electromagnetic waveform curve, etc., so as to realize the quantification and visualization of wire rope defect detection. The WRNDT system has smaller size, lower power consumption, and is more convenient to install and use. It is not only used in cranes, but also has a broad market in fields such as elevators, cableways, and bridge suspensions

The core equipment of the WRNDT steel wire rope online detection system is the new generation of micro special technology steel wire rope flaw detector. This flaw detector is a professional product based on independent intellectual property rights and commercially produced magnetic sensors, and is based on international standard magnetic memory flaw detection principles. Compared with the current MT level sensitivity of wire rope flaw detectors on the market, its PT level sensitivity has increased by millions of times Φ 5~ Φ 50mm steel wire ropes of various specifications can quickly detect one broken wire, and even strike marks can be easily identified, without the need for excitation devices, thus avoiding performance degradation caused by adsorption of metal powder and debris during long-term use

Metal magnetic memory effect refers to: during the processing and operation of ferromagnetic metal materials, due to the combined effect of load and Earth's magnetic field, the orientation and irreversible reorientation of magnetic domain structure with magnetostrictive properties will occur in the stress and deformation concentration area. This irreversible change of magnetic state will not only remain after the removal of working load, but also is related to the maximum applied stress. The magnetic state on the surface of metal components remembers the location of microscopic defects or stress concentrations, which is known as the magnetic memory effect. When the ferromagnetic components in the Earth's magnetic field environment are subjected to external loads, the orientation and irreversible reorientation of the magnetic domain structure with magnetostrictive properties will occur in the stress concentration area, and the fixed nodes of the magnetic domain will appear in this part, producing magnetic poles, forming demagnetization field, so that the permeability of the ferromagnetic metal in this part is the smallest, and a magnetic leakage field will be formed on the metal surface. The tangential component Hpx of the leakage magnetic field intensity has a maximum value, while the normal component Hpy changes sign and has a zero value. This irreversible change in magnetic state remains remembered even after the working load is eliminated

The WRNDT system is a detection instrument based on the basic principle of metal magnetic memory effect. By recording the distribution of magnetic field intensity components perpendicular to the surface of metal components in a certain direction, it can evaluate the degree of stress concentration and whether there are micro defects in the components. It can diagnose the stress concentration areas inside ferromagnetic metal components, such as micro defects and early failure and damage, Prevent sudden fatigue damage

Boutique Zhonglian 35H, May 20th National Day, with a counterweight of 8 tons, an arm length of 44 meters, 1000 hours, and 7000 kilometers The vehicle is executable from inspection to ensure no accidents, and has completed procedures for insurance review By May next year, the full price of the car will be sold for 680000 packages and upgraded

 

 

info@zanchen-parts.com

1 11295465 Pipe GP, steel 1

2 B210780000047 Connector, pipe 1

3 A210204000163 Screw 8

4 A229900002856 Flange, split 4

5 A229900002039 Clamp, pipe, single section 2

6 11295397 Pipe GP, steel 1

7 11295394 Pipe GP, steel 1

8 A229900002561 Connector, pipe 2

9 A229900002789 Connector, pipe 3

info@zanchen-parts.com

10 B230103003027 Hose, rubber 1

11 21020726 Hose, rubber 1

12 21030915 Pipe, rubber 1

13 B230103000381 Hose, rubber 1

14 21003064 Connector, pipe 1

15 A229900002559 Connector, pipe 1

16 A229900002752 Connector, flange, right angle 1

17 21002923 Connector, flange, right angle 1

18 B230103008560 Hose, rubber 1

19 11295732 Pipe GP, steel 1

20 A210770000631 Connector, pipe 1

info@zanchen-parts.com

21 A229900004342 Connector, pipe 1

22 B210780000051 Connector, pipe 2

23 11295381 Pipe GP, steel 1

24 11295748 Pipe GP, steel 1

25 B230103002554 Hose 1

26 B230103000391 Hose, rubber 1

info@zanchen-parts.com

27 B230103002633 Hose, rubber 1

28 B230103000462 Hose, rubber 1

29 A229900002420 Clamp, pipe, single section 3

30 11295375 Pipe GP, steel 1

31 A229900002040 Clamp, pipe, single section 1

32 B210780000029 Connector, pipe 5

33 11295364 Pipe GP, steel 1

34 11295360 Pipe GP, steel 1

35 11295450 Steel pipe assy. 1

36 A229900002415 Clamp, hose, single 3

37 11623449 Pipe GP, steel 1

38 11622638 Pipe GP, steel 1

39 B230103000444 Hose, rubber 1

40 B230103002997 Hose, rubber 1

info@zanchen-parts.com

41 60033558 Balanced valve, luffing 1

42 A210204000017 Screw 4

43 A229900002541 Connector, pipe 1

44 A229900002570 Connector, pipe 1

1 10138667 Pressure reduction block, brake 1

2 A229900002415 Clamp, hose, single 2

3 A229900002420 Clamp, pipe, single section 4

4 11295924 Pipe GP, steel 1

5 11295927 Pipe GP, steel 1

6 11295929 Pipe GP, steel 1

7 11301213 Steel pipe assy. 1

8 11305826 Valve GP, shuttle 1

info@zanchen-parts.com

9 60029453 Motor, plunger 1

10 A229900002581 Connector, pipe 2

11 A229900002537 Connector, pipe 1

12 A229900002559 Connector, pipe 6

13 A229900002561 Connector, pipe 2

14 A832313030000 Hose, rubber 1

15 B230103000391 Hose, rubber 2

16 B230103000472 Hose, rubber 3

17 B230103000478 Hose, rubber 1

18 B230103005334 Hose, rubber 2

1 A229900002495 Connector, pipe 3

2 A229900002547 Plug 1

3 A229900002606 Plug 1

4 B220401000913 Valve, relief 1

info@zanchen-parts.com

5 B220401000045 Valve, one-way 1

6 10890177 Plug, screw, damping 1

7 10121343 Relief block, brake 1

8 B220401000130 Valve, overflow 1

1 A229900002570 Connector, pipe 3

2 B220401000345 Valve, shuttle 1

1 A210416000023 Ring, retainer 1

2 60168804 Shaft Seal Cover 1

info@zanchen-parts.com

3 60168802 Oil Seal 1

4 A210609000141 O-ring 1

5 60168725 Adjusting Washer 2

6 A210414000029 Ring, retainer 1

7 60168726 Adjusting Washer 1

info@zanchen-parts.com

8 60168783 Bearing Seat 1

9 60168692 Conical Roller Bearing 1

10 60168693 Conical Roller Bearing 1

11 60168702 Z Main Shaft 1

12 60168789 Plunger 7

13 60168684 Central Rod 1

14 60168776 Pressure Plate 1

info@zanchen-parts.com

15 60168765 Hexagon Socket Button Head Screws 7

16 60168790 Plunger Ring 14

17 60168709 Spring 1

18 60168713 Spring Seat 1

19 60168732 Cylinder Body 1

info@zanchen-parts.com

20 60168738 Housing 1

21 60168807 Nameplate 1

22 A210510000010 Rivet 4

60029453 Motor, plunger