Wire Rope Online Inspection System For harbour
2. The inspection is completed during production, thus leading the two processes of production and inspection combined into one, effectively improving the utilization rate of equipment.
3. It can reduce energy consumption of the equipment used for wire rope detection, save energy and reduce consumption significantly;
4. It can scientifically extend the service life of wire rope and reduce the cost of wire rope.
Technical Parameters
(1) Inspection range of wire rope: Φ16-80mm;
(2) LMA inspection uncertainty: <±1%;
(3) Flaw positioning accuracy:≥99%;
(4) Inspection speed: 0-6m/s;
(5) Monitoring speed: 0-20m/s;
(6) Passing-through capability: Non-interferencewith warp, grease or deformation;
(7) Clearance between sensor and wire rope: 10-30mm;
(8) Max. amplitude of wire rope: <10mm;
(9) Sensor sensitivity: 1.5V/mT;
(10) Signal-to-noise ratio: S/N>85dB;
(11) Max. sampling rate: 2048times/m;
(12) Working voltage: AC220V±10%/50/60 Hz;
(13) Communication network: WIFI or industrial Ethernet;
(14) Docking communication protocol: TCP/IP, Modbus;
(15) Ingress protection: IP67;
(16) Working environment: -40℃-+60℃/RH 95%;
(17) Continuous working hours: ≥168h;
(18) Service life of equipment: ≥10 years;
Flaw Detectability
● Severe flaw: LMA reaches 8%-10% , real-time detectability 100%
● Serious flaw: LMA reaches 6%-8% , real-time detectability 100%
● Medium flaw: LMA reaches 4%-6% , real-time detectability 100%
● Minor flaw: LMA reaches 2%-4% , real-time detectability >99%
● Slight flaw: LMA reaches =2% , real-time detectability >95%
LMA reaches >1% , real-time detectability >95%
Inspection Repeatability
● Severe flaw: 100%,flaws inspection waveforms basically coincide
● Serious flaw: 100%,flaws inspection waveforms basically coincide
● Medium flaw: 100%,flaws inspection waveforms basically coincide
● Minor flaw: >99%,flaws inspection waveforms basically coincide
● Slight flaw: >95%,flaws inspection waveforms basically coincide
Inspection Accuracy
●Steel wire rope, coiled tubing metal cross-sectional area (LMA) loss rate detection error: < ±1%
● Broken wires quantitative error i n one lay length: <1 wire*
●Steel wire rope, coiled tubing dia. measure error: ±1%*
●Steel wire rope, coiled tubing measuring error of wire rope length:<0.2%
●Flaw positioning accuracy:≥99%;
| Comparison | Manual inspection | 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. Real-time monitors safety hidden dangers of rope. Bring the safety of wire rope to the highest level. |
| 2. Decrease costs & increase benefits | Inspection speed is 0.3m/s, high energy consumption, low efficiency. The annual average inspection 16.5 times, each time takes 4h, the whole time consumption of inspection is 66h. Daily inspection: It takes 20 minutes for two shift of inspection in a day, and annual time consumption for inspection is 100h. It takes about 166h to inspect STS crane rope inspection: The STS crane stops operation while inspecting rope. | 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 cranes in MS port can be increased by 229.82 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&emissionreduction | Winch motor power: Hoisting motor 580kW, rope inspection time 2h/time, energy consumption 1160kWh; Trolley motor 270 kW, rope inspection time 2h/time, energy consumption 520kWh; Luffing mortor 360 kW, rope inspection time 0.7h/time, energy consumption 253kWh; Annual inspection: 16.5 times, energy consumption 32231.1 kWh. | Each STS crane can reduce 32231.1 kWh inspection energy consumption annually; 36 units STS cranes in MS port can save rope inspection energy every year: 1160319 kWh; Carbon dioxide emission reduction: 1,156,700 kg. Carbon emission reduction: 315,535kg. |
| 5.Human cost | Regular rope inspection needs 6 people to spend 4h to perform each time, annual working time is about 396h; Average daily inspection time is 100h each year, and average working time is about 298h annually; Manual rope inspection will occupy STS operation time average 694h. | Machine intelligent inspection replaces manual examination. Saving averagely rope inspection operation time 694h |
| 6.Scientificmanagement | Scattered rope inspection records, poor traceability, unable to manage the life cycle of wire rope scientifically. | Inspection big data support, testing records can be traced, and the wire rope safe service life can be evaluated correctly. |
