Who I am——Magnetic Memory Wire Rope AI Weak Magnetic Inspection Technology

    Bring Wire Rope Safety to the Highest Level

    What can I do-——It can inspect all kinds of wire rope flaws such as internal, external broken wire, abrasion, corrosion, deformation, fatigue etc.

    Flaw detection rate Repetition rate Accuracy rate

    Flaw detection rate

    -Severe flaw: LMA reaches 80%-100% of discard upper limit, real-time detectability 100%

    -Serious flaw: LMA reaches 60%-80% of discard upper limit, real-time detectability 100%

    -Medium flaw: LMA reaches 40%-60% of discard upper limit, real-time detectability 100%

    -Minor flaw: LMA reaches 20%-40% of discard upper limit, real-time detectability >99%

    -Slight flaw: LMA reaches 20% of discard upper limit, real-time detectability >90%

    Repetition rate

    -Severe flaw: 100%

    -Serious flaw: 100%

    -Medium flaw: 100%

    -Minor flaw: >99%

    -Slight flaw: >90%

    Inspection accuracy

    -Wire rope LMA Inspection uncertainty :±1%

    -Number of broken wires in splice uncertainty: <1 wire*

    -Measuring tolerance of wire rope diameter:±1%

    -Positioning accuracy of defects: ≥99%

    Note: *indicates the adding of AI machine visual inspection system

    How to choose an excellent testing equipment

    In China good and poor wire rope quality inspection devices are mixed, some fakes equipment pretended real ones , bad money drives out good money. If the customer chooses one test equipment that is not easy to use or even cannot be used, it will not only achieve the safety management goal of the wire rope, but will increase the new safety hazard. At the same time, purchasing a backward technology device will also bring unnecessary economic loss to enterprise。

    "The way to distinguish a horse and mule is to pull them out and make them walk" It is the great wisdom of the Chinese to make the right choice. "Marrying by contesting” or "verification results" is the correct way to choose excellent equipment. Seeing is believing, and the result is the first, Using the flaw detection rate, repetition rate, accuracy rate to verify the quality of the equipment, the poor quality equipment are very easy to expose.

    • Good advanced technology TCK.W
    • Poor technology
    • Verifying detection rate
    • Can inspect all kinds of wire rope flaws such as internal, external broken wire, abrasion, corrosion, deformation, fatigue etc.

    • Most of them can only inspect broken wires on surface of rope, but do nothing to other defects of rope

    • Verifying repetition rate
    • Good advanced technology: inspect the same rope repeatedly for many times, and the results of each test are basically the same

    • Repeat the test for the same wire rope; the results of each test are different.

    • Verifying accuracy rate
    • Repeat detection on the same wire rope, the flaw value of each test is basically the same;

    • The wire rope cannot be quantitatively tested, or the value of the flaws detected by each test is different.

    • Can monitor rope online
    • The distance between the sensor and the surface of the wire rope is >30mm, the passing ability of device is strong, and the high-speed passage of the wire rope is not affected, so online monitoring can be realized;

    • The detection distance of the sensor is less than 2mm, the passing ability of device is weak, and the vibration and the swing of the wire rope caused by high speed passing will damage the testing head, so online testing cannot be realized;

    What can i do——Quantitative detection of various conveyor belt damages with accurate positioning such as displacement of splice, broken cords, surface defects, longitudinal tearing, etc.

    • Winner of 2018 OTC Innovation Award on New Technology

    • Wire Rope Online Inspection System For Offshore

    • Wire Rope Online Monitoring System

    • Wire Rope Online Automatic Inspection System

    • Ropeway Wire Rope Inspection Intelligent Expert

    • TCK.W-ZN wire rope tester

    • TWire Rope Inspection site

    • Detector forLarge Diameter Rope

    • Elevator Wire Rope Intelligent Inspection Expert System

    • Steel Core Conveyor Belt Intelligent Monitoring System(Transverse fracture)

    • Steel Core Conveyor Belt Intelligent Monitoring System(laws locating accurately)

    • Steel Core Conveyor Belt Intelligent Monitoring System(laws locating accurately)

    TCK.W weak magnetic inspection technology——It is safe, but more benefit!

    More than 50 users published papers in various journals, highly praised TCK.W weak magnetic inspection technology

    It is safe, but more benefit!

    Replacing manual inspection with machine intelligence testing

    Wire rope safety is upgraded to the highest level.

    The two processes of production and testing are combined into one, Reduce time for wire rope testing, you can increase the operating time, improve productivity.

    Reduce the idle time of equipment and power consumption for wire rope inspection, significant energy saving effect;

    Scientifically extend the service life of wire rope, significant effect of reducing the cost of wire rope

    All you get is wealth

    It is investment, but also income.

    Yang Buzhong published a paper in the 7th issue of "Machinery Management and Development" in 2015: "the application of TCK. W system has brought huge economic benefits to Yungang Mine of Tong Coal Group Company. There are four winches in the main shaft, auxiliary shaft and slope shaft used for materials transportation, which can save energy consumption of 1 million kW/h for wire rope inspection every year; reduce downtime for inspection by about 973h, and increase raw coal output by 304000t. According to the current coal price of 475 Yuan/t with calorific value 5500 kcal/kg, the annual output value is increased by 144.4 million yuan. The effect of saving rope cost and labor cost is also very significant. "

    "Machinery Management and Development" Issue No. 7, 2015

    Author:Mr. Buzhong Yang,Yungang Mining, Datong Coal Mining Group, China,

    Outstanding safety, economic, environmental protection and management benefits

    • Comparison
    • Traditional manual inspection TCK.W
    • TCK.W innovative technology
    • 1. Safety concern
    • Extern al defects can be detected partially and internal defects cannot be detected; non-continuous inspection time, difficult to monitor defects development trends.
    • Hidden danger of wire rope broken accident can be avoided. Wire rope safety has been upgraded to its highest level.
    • 2.Cost decreasing and benefit increasing
    • The inspection speed is 0.3m/s. Rope inspections are executed in two shifts per day, each inspection consumes 0.5 hour in each shift, 1 hour per day. Inspection will cost 330 hours in 330working days each year.
    • The inspection speed can be 3-6m/s when it passes the sensors, the inspection will only take 3 minutes for two shifts each day with less than 20 hours per year, in this case on average more than 330 working hours can be added for each oil drilling rig every year.
    • 3.Energy saving and emission reduction consumption
    • Regular change of wire rope, resulting in huge waste.
    • Save rope inspection energy consumption of about 189410 kWh, save carbon dioxide emission of 188842kg and carbon emission of 51520kg.
    • 4. Human cost reduction
    • 611 Kwh energy are consumed each day for manual inspection, and totally 201630 kWh each year.
    • Manual inspection is replaced with machine intelligent inspection.
    • 5. Wire rope cost reduction
    • Two persons are needed for drilling rope inspection each day, and it takes 2 hours for it. Total inspection time is 660 hours.
    • Wire rope whole lifecycle safety monitoring and wire rope costs reduction.
    • 6. Scientific management
    • Rope inspection records are scattered, with poor retrieval.
    • Wire rope inspection records and data retrieval can be ensured;It can help to keep wire rope safety to its highest level.

    MS port case analysis: safety benefits, economic benefit, environmental benefit, outstanding management benefit

    • Comparison
    • Manual inspection TCK.W
    • TCK.W innovative technology
    • 1.Safety pain points
    • The reliability of manual inspection is poor, and the internal flaws cannot be detected; the process safety is uncontrolled, and the major hidden dangers are difficult to be eliminated.
    • Comprehensively inspect all kinds of internal and external flaws of rope, replace manual inspection with machine intelligent one, and reach the highest level of wire rope safety.
    • 2.Decrease costs & increase benefits
    • The testing speed is 0.3m/s, it is high energy consumption, low efficiency and long inspection time; Regular inspection: the annual average inspection is 16.5 times, with each inspection for 2 hours, and the annual inspection time is about 33 hours; Daily inspection: it takes 20 minutes for two shifts of inspection in a day, which is calculated as 300d / year and takes 100h; The inspection time of wire rope of quay crane is about 133h every year; the operation of container hoisting is stopped during the inspection.
    • The inspection is completed during the hoisting operation, saving 133h of inspection time in the whole year; based on an average of 30TEU / h, each quay crane can increase 3990 TEU lifting every year; based on hoisting fee 1600 Yuan / TEU, the output value can be increased by 6.384 million Yuan. The service life of TCK. W equipment is 10 years, and the annual input-output ratio is greater than 1:88. The annual output value of 36 quay crane in MS port can be increased by 22982 million Yuan if TCK. W equipment are used in all quay cranes.
    • 3.Rope cost
    • Regular or quantitative rope replacement ensures safety by sacrificing cost, and the waste of wire rope is serious.
    • Monitoring the safety of wire rope during its service time; Decrease the rope cost scientifically
    • 4.Energysaving & emission reduction
    • Winch motor power: lifting motor 580kw; trolley motor 270kW, luffing motor 360kW. The power consumption of lifting rope / trolley rope inspection is 1105kW in 1.3h and luffing rope inspection is 253.4kW in 0.7h. The annual energy consumption is 22410 kW h for 16.5 times inspection.
    • Each quay crane can reduce 22410kw / h of energy consumption for wire rope inspection every year; 36 units quay crane in MS port can save detection energy every year: 806800 kW h; Carbon dioxide emission reduction: 804300 kg. Carbon emission reduction: 219400 kg.
    • 5.Human cost
    • It takes 2 hours, needs 6 person to do regular ropes inspection each time, average annual 198 hours: taking average annual 100 hours for daily inspection, annual manual inspection time:298hours.
    • Machine intelligence inspection replace manual testing.
    • 6.Scientific management
    • Scattered rope inspection records, poor traceability, unable to manage the life cycle of wire rope scientifically.
    • Inspection big data support, test results can be traced, and the life cycle of wire rope can be evaluated.

    TCK.W has provided technology and service for 2500 customers among 42 countries