Wire Rope Tester

Applications of TCK•W-BX Portable Wire Rope Testers

TCK•W® portable wire rope testers have been used widely in many industries, such as mining, petroleum, steel plants, heavy equipment manufacturing, ports, transportation, construction, water conservancy, resort, aerospace, and the military. Worldwide。

Application Locale in Intelligent Wire Rope Tester

Application Locale in Coal Mining Industry

Application Locale in Port Industry

Application Locale in Petroleum Industry

Application Locale in Cableway/Ropeway Industry

Application Locale in Lifting Industry

Application Locale in Metallurgical Industry

Application Locale in Ship Building Industry

Wire Rope Tester Operation Locale of Other Industries

TCK•W® Wire Rope Tester

A great scientific innovation must lead to a great technological breakthrough. TCK•W® portable rope testers weigh only 1.8 KG, about 1/6~1/25 of the weight of conventional NDT testers. The sensitivity of TCK•W® sensors could reach 5V/mT, and about 700times higher than conventional sensors. The gap between sensor and wire rope is about 20-30mm which achieves non-contact inspection, it does not affected by grease, normal warped wire, and rope-running speed which shown that passing-through capacity is good. When an inspection is completed, TCK•W® rope testers are capable to display testing data, flaw graph, data table, and test report on LCD screen. After connected to a computer and printer, a formal test report could be printed, which provides scientific reference for users to use wire ropes more safely and replace wire rope more properly.

Global Leading NDT Technology

Taking the wire rope safety bearing capacity inspection principle as inspection standard, TCK•W® Weak Magnetic Flaw Detector can quantitative detect percentage loss of effective metallic bearing cross-sectional area caused by wire rope's internal or external breakages, abrasion, corrosion and fatigue and other flaws and can correctly evaluate the residual bearing capacity and service life of the inspected wire rope. Its inspection result provides scientific references for safe use and reasonable displacing of wire rope in accordance with the requirements of standards and specifications concerned. TCK•W® Weak Magnetic Flaw Detector is a hi-tech guarantee of effectively preventing accident of breakage wire, properly reducing use cost of wire rope and scientifically enhancing service efficiency of wire rope.

Three Innovations & Two Breakthroughs

TCK•W® non-destructive inspection technology is an important innovative achievement in the field of wire rope inspection, based on successful discovery on the changes and movement rules of Space Magnetic Field Vector Status. This leading weak magnetic flaws detection technology focuses on 3 innovations and 2 breakthroughs:

1、Establish new theory of "Spatial Magnetic Field Vector Resultant".

2、Discover new method of "Weak Magnetism Inspection".

3、Invent the new technology of "Weak Magnetic Sensor".

Thanks to the 3 innovations, TCK•W® successfully solved the two difficult problems that have puzzled entire world for over a century in non-destructive detecting field:

1、Quantitative detection on various wire rope flaws.

2、Accurately evaluate the residual bearing capacity, safety coefficient and in-service life of the wire rope.

First-class corporate sets standards

TCK•W® takes an active part in drafting China's Coal Industry Professional Standard (MT/T970-2005): Wire Rope Non-destructive Quantitative in-service Inspection Methods and Assessment Rules, which was issued by the National Development and Reform Commission of China. This is not only China's first wire rope inspection standard, but also the world's first standard with assessment rules. The base of this standard is TCK•W weak magnetic inspection technology; therefore, the technical grade of it is much higher than wire rope inspection standard issued by countries such as USA and Europeans. The standard’s publication marked that the Chinese wire rope inspection technology is at leading level in the world.

Functions of TCK•W® Portable Wire Rope Testers

1.Quantitatively detecting both external and internal flaws such as broken wires, abrasion, corrosion, fatigue, and other defects; and correctly evaluating the inspected wire rope’s residual bearing capacity, safety coefficient and service life;

2.Real time Sound/Light alarm function during the inspection process;

3.Online automatic calibrating technique to ensure the accuracy of inspection results;

4.Self-diagnosis function to ensure the system operate reliably;

5.Integrated design of testing instrument and meters, with no need for external power supply and cable connection;

6.With a working space of 20-30 mm between the testing heads and the wire rope surface and the opposite motion mode of the guide wheels and wire rope, TCK•W® portable rope testers have exceptional passing capability, which is not affected by broken wires, rope deformation, oil sludge, dirt and other factors, and capable of inspecting under any working conditions;

7.Trigger type self-unlocking device, which quickly unlock the tester from the rope in emergency situation to ensure the safety of the inspectors and the equipment;

8.Easy for operation because of simple instrument keyboard setting, rolling linear logic interface switch, indicative man-machine conversation, and embedded intelligent program operation;

9.As soon as an inspection is completed, the inspectors can check the inspection data, flaw curves, analysis report, and numerical inspection result on the tester’s LCD screen; if the tester is connected to a printer, a formal test report can be printed out;

10.High performance rechargeable Lithium Polymer battery unit;

11.Testing head employs high strength, insulated anti-corrosive material to prevent electricity leakage, short circuit, and electric shock by lightning;

12.Quantitative inspection methods and evaluation rules meet the requirements prescribed in MT/T970-2005 Non-destructive and Quantitative Inspection Methods and Evaluation Rules for Wire Rope and other industries’ standards and requirements;

13.The instrument is CE certified and has no electromagnetic pollution; it does not interfere with the normal operation of other electronic and communication equipments in the work locale;

14. Water, dust, oil and moisture proof.

TCK•W® excellent technological indexes

1.“Weak magnetism sensor” technology invented:uniquely by our company, its sensitivity is 700 times higher than traditional tester. The sensor has strong resolution, and can inspect quantitatively actual wire rope flaws under various working status.

2.Reliable performance: quantitative uncertainty for measuring the percentage loss of effective bearing metallic cross-sectional area (LMA) and other flaws such as broken wires, corrosion and abrasion (LF) : ±1%;

3.High level integration: all function modules are integrated, including system self-diagnosis module, digital automatic calibration module, “Eagle Eye” module, S/N quality module, signal fidelity module, and anti-interference module;

4.Fast data processing capability: by analyzing the original data extracted by TCK•W® testers from the wire rope, TCK•W® patented software is capable of evaluting the working condition of the rope in use. It will not only display the testing result and print out the test report in real time, but also exchange data between the tester and a PC at fast speed;

5.Small volume and light weight: the weight of TCK•W® portable flaw detector is less than 2kg, which is only 1/6—1/20 of that of similar products at home and abroad;

6.Wide applicability: applicable to wire rope inspections under complex working conditions and not be affected by the inspectors’ experience or skills, rope speed, noise, water spraying, warped wires, oil dirt and other factors;

7.Accurate inspection results: capable of quantitatively measuring the percentage loss of effective bearing metallic cross-sectional area (LMA), caused by internal and/or external broken wires, abrasion, corrosion, fatigue and other defects and thereby evaluate the residual bearing capacity and service life of the inspected wire rope.

technical performance parameters

1.Sensor working sensitivity:≥1.5V/mT

2.Defect equivalent uncertainty (P): ±1%

3.Defect locating accuracy: > 98%

4.Safe speed for hand-held inspection: < 2m/s

5.Sensor operating field strength <20mT

6.Accuracy

Over Limit Flaw Detecting Accuracy: 100% ( Loss of Effective Metallic Area over 10%)

Server Flaw Detecting Accuracy: 100% ( Loss of Effective Metallic Area between 8% to 10%)

Serious Flaw Detecting Accuracy: 100% ( Loss of Effective Metallic Area between 6% to 8%)

Medium Flaw Detecting Accuracy: >98% ( Loss of Effective Metallic Area between 4% to 6%, still within safety range)

Minor Flaw Detecting Accuracy: > 90% (Does not effect safety, Loss of Effective Metallic Area between 2% to 4%)

Slight Flaw Detecting Accuracy > 75% (Value less than 2%, could be disproption of wire rope, internal welding spot, and padding metals)

7.Gap between sensor and target wire rope>20mm, non-contact inspection, not effected by warped wire, grease, and operating speed, strong passing-through capacity.

8.Quickly take off from wire rope, ensure the safety of inspector and instrument.

9.As soon as an inspection is completed, the inspectors could check the inspection data, flaw curves, analysis report, and numerical inspection result; if the tester is connected to a printer, a formal test report could be printed out.

Test Report

TCK•W® Wire Rope Tester Analysis Software

1、TCK•W® (Lower Computer) Embedded Inspection Software

It is installed in TCK•W® portable testers and its main functions include calibrating the tester on the target rope (establishing the reference value or standard for inspecting the rope), real-time signal extracting, data storage and processing, data retrieval, memory management and equipment self-diagnosis.

Figure 1

2.TCK•W® Wire Rope Quantitative Inspection System V4.0 (Upper Computer)

analysis, data table management, data/report displaying and printing, and file management.

Figure 2Figure 3

3、Test Report

When an inspection is completed, TCK•W® rope testers are able to display on the LCD screen testing data, flaw graph, data table, and test report. After connecting to a computer and printer, a formal test report could be printed, which provides scientific reference for users to use wire ropes more safely and replace wire rope more appropriately.

User Reviews Report

China Luo Yang Wire Rope Inspection Technology Co.,Ltd.

Tel:86-379-65112379      E-mail:intl-dept@wmndt.com

Address:6/F,Buiding B2,Torch innovation Garden of Luoyang National High-Tech Development Zone ,Luoyang ,China.

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