Mine-used Hoist  Wire Rope  Online Real-time Safety Monitoring System

    Locale of wire rope on-line real-time safety monitoring system for ground mounted four-rope friction hoist

    Inspection locale of Wire Rope Online Real-time Monitoring System installed on 6-rope friction hoisting system.

    Inspection locale of Wire Rope Online Real-time Monitoring System installed on single rope winding hoisting system

    Locale of on-line real-time safety monitoring for Cableway wire rope

    Locale of on-line real-time safety inspection for overhead man riding wire rope

    Main Control Center of Wire Rope Online Realtime Automatic Inspection Ssytem

System Introduction

As a high risk component of hoisting, lifting and conveying equipments, wire rope is regarded as the“lifeline”in many industries. However, the safety of in-service wire ropes has always been the “blind spot”or“source of danger”in equipment management, because of the lack of reliable testing instrumentation. How to detect the deterioration of in-service wire ropes and ensure their safety is an urgent demand for wire rope users.

Invention of TCK•W® Wire Rope on-line real-time safety monitoring system has fundamentally changed the backward situation of wire rope inspection management。

The delectability of the TCK•W® on-line system is much higher for Localized Flaws (LF) and its precision is much accurate for the Loss of Metallic Cross-Sectional Area (LMA) and rope diameter reduction. It has solved the three problems of wire rope application –“hidden dangers, waste and low efficiency” for oil drilling (repairing) customers and helped wire rope users achieve “safety, economy and efficiency.”It has been recognized as the most advanced wire rope NDT inspection system in the world.

TCK•W® can help customer to meet the values

Make the steel wire rope under a fully controlled and safe condition in operation process.

》Combining the production process and inspection process into one, which will reduce one process, increase effective operation time and enhance the productivity.

》Reducing the idling energy consumption of equipment specifically for testing wire rope, and effect of energy saving is obvious.

》Making the service life of wire rope more effective and proper, saving wire rope replacing time and reduce the cost of wire rope.

Remarkable economical benefit

Take Fengfeng group as an example, after Jiulong Mine, Xuecun Mine and Dashucun Mine equipped TCK•W® Wire Rope Online Automatic Monitoring System, the company not only solved the long plagued problems of the wire rope safety operation, and created considerable economic benefits.

1.The average annual saved of wire rope testing time 1320 hours, increased production capacity 5.6%, only for this point, they increased the volume of production for 28.8 tons every year.

2. Reduced the steel wire rope detection equipment idle energy consumption of 726000 kwh.

3. Saved 1/3 cost of rope replacing cost. The ROI rate is reaching 1:90which really achieved the purpose of small input and huge return.

① TCK•W® Modular Inspection Device

-Real-time monitoring wire rope safety status while wire rope is running at high speed;

-The operation of wire rope is always at a safe and controlled monitoring status;

-Weak Magnetic Sensor with high sensitivity, high stability characteristic, not influenced by the operation speed;

-Wide-spacing and non-contact inspection to ensure safety operation of the inspection device;

-On-line positioning installation and automatic operation;

-Suitable for all-weather indoor and outdoor working environments, with rain-proof, shock-proof, and oil-proof design。

-Routine maintenance free.

② TCK•W® Intelligent data collection & conversion workstation

-Intelligent multi-channel two-way automatic information communication mode;

-Modular multi-function unit combination, easy for updating;

-Shield-type information receiving & conversion and anti-interference design。

-Embedded real-time alarming program, with “yellow light” for early warning flaws and “red light” for over-limit warning flaws.

③TCK•W® Photoelectrical Distance/Speed Measuring Device

-Adopt high-precision photoelectrical encoder and light aluminum frame;

-Anti-loosening mechanical structure, self-clamp-floating cantilever support, and friction wheel with multi-channel anti-slip rings;

-Integrate anti-shake, pulse shaping, and equal accuracy tachometer…etc industrial design with features of stable signal and light accuracy meter/speed measuring.

④ TCK•W® Self-controlled Sound And Light Alarm System

-Real-time and graded alarming responses, with “yellow light” for early flaw warning and “red light” for over-limit flaw warning.

-With over-limit flaws, the “red light” will be on and pre-programmed .safety measures will be acted simultaneously.

-High-power on-site sound and light displaying device。

SMS safety report function device

-Based on the real-time monitoring results and historical statistics, the alarm information will be showed and locked in terminal interface. The corresponding alarm information can be remotely sent to manager's mobile phone by SMS according to the system pre-setting.

⑤TCK•W® Multi-channel Terminal Workstation

-Multi-channel step-by-step calling, synchronous and high speed data receiving & sending operation mode, optional configuration for wire/wireless communication.

-Dedicated command and control software, manual/auto switch operation mode.

-Tsimple man-machine interactive mode.

-Compatible with the LAN or public network for information sharing.

-Real-time testing data collecting, analyzing and processing, with file-type data management system.

-Support testing data retrieving and test report printing whenever needed.

-The temporal trend analysis of all kinds of safety hidden danger on wire rope tested can be offered.

technical performance parameters

1、Sensor working sensitivity:≥1.5V/mT

2、Maximum sampling frequency: the time domain 8000 times/s,spatial domain 2048times/m

3、Inspection accuracy rate of major rope failure accident:100%

4、Defect locating accuracy: > 98%

5、Defect equivalent uncertainty (P): ±1%

6、Wire rope shock swing limit:10~25mm

7、Rope Speed for Inspection:0-3m/s.

8、Rope Speed for Monitoring:3-20m/s.

9、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)

10、System working voltage:

AC220V ± 10% (non-explosion-proof),

AC127V ± 10% (explosion-proof)

11、System rated power: <350W

12、Inspection range of target wire rope diameter: φ16 ~ 100mm

13、Signal transmission distance:Allowed Length: 50m ,Optical fiber allowed length: 40 km

14、Dimension between ropes: <φ175mm x1200mm

15、Sensor Operating temperature: -20 ℃ ~ +55 ℃

16、Ingress Protection: Ip67

Specifications and Parameters

Test Report

Wire Rope W-TY Wire Rope on-line real-time safety monitoring systemV4.0, adopted professional computer-controlled applications, achieved unattended, automatic inspection, automatic data integration, automatic generating inspection reports and other systematic functions, can provide the customer visual test report in different aspects.

This software is protected by the national software copyright(Registered number: 2013SR94420)

W-TY Wire Rope on-line real-time safety monitoring system V4.0 is able to provide users with the most visual damage of wire rope inspection report from different angles:

Inspection Report

Real Time Inspection Curve Chart

Grading Statistics List of Flaw

Flaw sequence table

Weak Magnetic Perspective View Of Current Status

Main Control Center of Wire Rope Online Realtime Automatic Inspection Ssytem

Wire Rope on-line real-time safety monitoring system Engineering Applications Design

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Our company’s weak magnetic inspection technology first time reaches wire rope online realtime automatic monitoring,and it has been widely used in lifting and transportation field of hoisting, oil drilling, passenger cableway, cargo transportation ropeway, steel mills.

Drilling rig (workover rig) of oil platform wire rope online realtime safety monitoring system

Fengfeng Group Equipped With TCK·W® Inspection System has Sovled Three Major Problems Of Hidden Hazards, Waste,and Inefficiency On Hoisting Wire Ropes,creating huge economic benefits annually.

Take Fengfeng group as an example, after Jiulong Mine, Xuecun Mine and Dashucun Mine equipped TCK•W® Wire Rope Online Automatic Monitoring System, the company not only solved the long plagued problems of the wire rope safety operation, and created considerable economic benefits.

1.The average annual saved of wire rope testing time 1320 hours, increased production capacity 5.6%, only for this point, they increased the volume of production for 28.8 tons every year.

2.Reduced the steel wire rope detection equipment idle energy consumption of 726000 kwh.

3.Saved 1/3 cost of rope replacing cost. The ROI rate is reaching 1:90which really achieved the purpose of small input and huge return.

Datong Mining Group equipped Wire Rope Online Inspection Equipment in large scale to build created new management and new mode.

A few days ago Datong Mining Group installed wire rope online realtime inspection system at 25 pairs of major mines. This is the first time in world wide range to reach the goal of wire rope online inspection for mining hoisting machine which is the landmark for wire rope safety management of large mining groups.

Hoisting wire rope safety management is always a big problem for Datong Mining Group(DMG). In order to solve this problem, Datong mining Group keeps looking for scientifical wire rope testing equipments. DMG compared the technical information of different wire rope testers home and abroad, finally it chose advanced week magnetic inspection. Also it invested 8 million RMB to equip wire rope online realtime automatic inspection system at 25 pairs of main mines of DMG, such as Meiyukou Mine, Yongdingzhuang Mine, Tongjialiang Mine, Silaogou Mine. The installed systems were able to monitor hoisting wire rope all the way and eliminated safety hazard, waste and low efficiency issues during the wire rope operation process, and then achieved management goals of safety, economy and production efficiency. For example, Laogou Mine has a 6-rope hoisting machine. In the past the wire rope inspection time is about 1.8 hours/day. After installed wire rope online realtime automatic inspection systems, this mine increased 8% of production capacity and Annual increased revenue was 120 million RMB. Therefore, the systems will increase production efficience, eliminate human labor consumption, save energy consumption about 0.59 million KWH for equipment idling and save 30% of wire rope replacement cost annually.

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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