Design and development of non-destructive testing instrument for multi-diameter mining wire ropes

doi:10.3785/j.issn.1006-754X.2025.05.105

Chinese Journal of Engineering Design

2025, Vol. 32

Issue (4): 532-541 DOI: 10.3785/j.issn.1006-754X.2025.05.105

Mechanical parts and equipment design

Design and development of non-destructive testing instrument for multi-diameter mining wire ropes

Nan YAO^1,²(

),Yunsheng YANG¹,Yang LIU^1,²(

),Yicheng YE^1,²,Jie FENG³,Qianshun TAO¹

^1.School of Resources and Environmental Engineering, Wuhan University of Science and Technology, Wuhan 430081, China
^2.Hubei Provincial Key Laboratory of Efficient Utilization and Block Building of Metallurgical Mineral Resources, Wuhan University of Science and Technology, Wuhan 430081, China
^3.Hubei Provincial Emergency Rescue Center, Wuhan 430000, China

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Abstract

In view of the problems of complex operation process and limited detection diameter range of existing quality inspection equipment for mining wire ropes, an on-line intelligent non-destructive testing instrument suitable for multi-diameter mining wire ropes has been designed and developed, which mainly includes an open-loop permanent magnetization system, hardware peripherals, application software and filtering algorithms. According to the physical characteristics of permanent magnetic flux leakage detection, a two-dimensional finite element simulation model of the permanent magnetization system with open-loop magnetic circuit characteristics was established through the ANSYS Maxwell software. The damage characteristic curves of the magnetized wire rope under different lift-off values were analyzed, and the optimal lift-off value was determined. In order to improve the noise reduction effect, a signal waveform smoothing processing method based on difference limit filtering algorithm was proposed. The results of multiple groups of tests show that the designed non-destructive testing instrument for multi-diameter mining wire ropes can effectively identify the broken wire damage of wire ropes with different diameters, and the average relative error of damage position detection is 0.36%, which has broad application prospects.

Key words： multi-diameter mining wire rope non-destructive testing instrument magnetic flux leakage detection filtering algorithm

Received: 13 January 2025 Published: 01 September 2025

CLC:

TG 115.28

Corresponding Authors: Yang LIU E-mail: yaonan@wust.edu.cn;liuyang@wust.edu.cn

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	Nan YAO
	Yunsheng YANG
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	Yicheng YE
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Cite this article:

Nan YAO,Yunsheng YANG,Yang LIU,Yicheng YE,Jie FENG,Qianshun TAO. Design and development of non-destructive testing instrument for multi-diameter mining wire ropes. Chinese Journal of Engineering Design, 2025, 32(4): 532-541.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2025.05.105 OR https://www.zjujournals.com/gcsjxb/Y2025/V32/I4/532

多直径矿用钢丝绳无损检测仪的设计与开发

针对现有矿用钢丝绳质量检测设备操作过程复杂、检测直径范围有限等问题，设计并开发了一种适用于多直径矿用钢丝绳的在线智能无损检测仪，其主要包括开环永磁磁化系统、硬件外设、应用软件及滤波算法等。根据永磁漏磁检测的物理特性，通过ANSYS Maxwell软件建立了具有开环磁路特征的永磁磁化系统二维有限元仿真模型，分析了不同提离值下磁化钢丝绳的损伤特征曲线，确定了最佳提离值。为提高降噪效果，提出了基于差值极限滤波算法的信号波形平滑处理方法。多组试验结果表明，所设计的多直径矿用钢丝绳无损检测仪能够有效识别不同直径钢丝绳的断丝损伤，损伤位置检测的平均相对误差为0.36%，具有广阔的应用前景。

关键词： 多直径矿用钢丝绳, 无损检测仪, 漏磁检测, 滤波算法

Fig.1 Overall structure of non-destructive testing instrument for multi-diameter mining wire ropes

Fig.2 Principle of permanent magnetic flux leakage detection for wire rope

Table 1 Key parameters of finite element simulation model of open-loop permanent magnetization system

Fig.3 Finite element simulation model of open-loop permanent magnetization system

Fig.4 Distribution of magnetic field line in excitation circuit of wire rope

Fig.5 Vector distribution diagram of magnetic flux in excitation circuit of wire rope

Fig.6 Distribution of magnetic field intensity in excitation circuit of wire rope

Fig.7 Effect of lift-off value on leakage magnetic field intensity

Fig.8 Structure diagram of open-loop permanent magnetization system

Fig.9 Physical picture of non-destructive testing instrument for multi-diameter mining wire ropes

Fig.10 Comparison of detection waveform before and after filtering processing

Fig.11 User interface

Fig.12 Magnetic flux leakage detection process for wire rope

Fig.13 Damage of wire ropes with different diameters

Fig.14 On-site of wire rope damage detection

Fig.15 Detection waveform of single broken wire in wire rope with a diameter of 16 mm

Fig. 16 Detection waveform of single broken wire in wire rope with a diameter of 28 mm

Fig.17 Detection waveform of single broken wire in wire rope with a diameter of 36 mm

Fig.18 Detection waveform of multiple broken wires in wire rope with a diameter of 16 mm

Fig.19 Detection waveform of multiple broken wires in wire rope with a diameter of 28 mm

Fig.20 Detection waveform of multiple broken wires in wire rope with a diameter of 36 mm

Fig.21 Two broken wire positions of wire rope

Table 2 Results of wire rope damage location


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