Abstract: This article introduces the current status of wire rope detection technology, explains the advantages of weak magnetic steel wire rope detection technology and the working principle of the wire rope online automatic detection system. The fact that Tongmei Group has created significant safety and economic benefits by using the TCK.W wire rope online automatic detection system proves that wire rope detection technology based on weak magnetic technology is an inevitable choice for coal mines to create a new model for improving wire rope safety supervision. Wire rope flaw detection equipment

　　1 Overview of improving wire rope damage detection

　　Steel wire rope is an irreplaceable component of coal mine transportation and improvement. It always maintains the safety of employees' lives and the safety of corporate property. It has always been highly valued by coal mining enterprises. For a long time, coal mining enterprises have followed the "Coal Mine Safety Operating Procedures" and used manual methods of visual inspection, hand touch, and caliper measurement to inspect the external damage of the wire rope to judge the safety condition of the lifting wire rope; or replace it regularly according to the specified service life. . Practice has proved that manual detection and regular replacement are unreliable and difficult to achieve the purpose of preventing wire rope breakage accidents. Therefore, coal mining enterprises urgently need to use wire rope non-destructive testing equipment to solve the three major problems of "hidden dangers, inefficiency, and waste" in improving wire rope usage management.

　　The special structure of the lifting wire rope determines that only by using non-destructive testing equipment to continuously detect the internal and external hidden dangers of the wire rope in real time and grasp its deterioration situation, can we proactively take decisive measures to effectively eliminate possible rope breaking accidents. After years of exploration, Tongmei Group selected the TCK online real-time automatic detection system for wire ropes based on weak magnetic technology to innovate and improve the wire rope safety supervision model, basically achieving the triple management goals of "safety, economy, and efficiency".

　　2 Improve the selection of wire rope detection technology

　　Non-destructive testing technology for wire ropes is divided into non-magnetic and magnetic. Non-magnetic detection mainly includes eddy current, mechanical vibration, ultrasonic, optical and other flaw detection methods, which have basically not been applied and promoted in industrial sites. However, magnetic detection technology is recognized as the most suitable for ferromagnetic detection because it can better adapt to working conditions. Detection technology for non-destructive testing of materials. Magnetic detection has two detection technologies: strong magnetism and weak magnetism. The former has a history of more than 100 years. Although it has made some progress, the technical breakthrough is not obvious. It always has defects such as poor passability, wave noise, and detection results are affected by speed. It is almost impossible to realize online detection of wire ropes. The weak magnetic detection technology, which was born at the beginning of this century, uses highly sensitive sensors independently developed in my country to comprehensively innovate detection principles and methods. It has made major breakthroughs in technology and achieved quantitative detection of internal and external damage to steel wire ropes, especially fatigue. TCK weak magnetic detection technology uses "Dou's element" sensor, which has high sensitivity. The detection body has no binding force on the tested steel wire rope. It can realize non-contact "wide range" detection. The detection equipment has good passability and the detection results will not be affected by the speed. , is considered by the industry to be the most promising advanced technology for realizing online real-time detection of wire ropes.

　　3 Advantages of weak magnetic detection technology

　　Non-destructive testing technology for wire ropes is divided into non-magnetic and magnetic. The basic requirement for online real-time detection of non-magnetic steel wire ropes is to continuously perform positioning, quantitative and qualitative detection of the running lifting wire ropes, and to ensure that the detection results are not affected by factors such as detection speed, wire rope shaking or jitter. The TCK steel wire rope online real-time automatic detection system based on weak magnetic technology fully realizes these functions. The reason why this system can achieve online automatic real-time detection is because the weak magnetic detection technology has unique advantages.

　　3.1 High-sensitivity sensor technology

　　The "Dou element" sensor is the core technology of weak magnetic detection. The "Dou element" sensor based on the principle of spatial magnetic field vector synthesis provides a given magnetic field by an energy-releasing element. The magnetic field associated with the weak magnetic space of the axial volume differential of the steel wire rope reflects the comprehensive degeneration characteristics of the steel wire rope, that is, local defects (LF) and effective metal cross-sectional area loss (LMA). The sensor's magnetic balance element can convert these changes into corresponding power signals.

　　Issue 4 Xue Peng, et al.: Application of TCK wire rope online automatic detection system in coal mine lifting wire rope safety management 45

　　Since the sensitivity of the "Dou element" sensor is very high, reaching 5V/GS, the wire rope online detection system based on weak magnetic technology uses non-contact "wide range" detection. The wire rope is very easy to pass and is not affected by any external factors. It can extract wire rope damage signals online in real time, accurately locate, quantitatively, and qualitatively detect various damages such as broken wires, wear, corrosion, and fatigue inside and outside the wire rope, and evaluate the remaining load-bearing capacity and service life of the wire rope. The detection speed of this system is 0~13m/s, and the detection is not affected by the shaking and shaking of the wire rope.

   　3.2 Space magnetic field vector synthesis theory

　　The new theory of space magnetic field vector synthesis founded by TCK.W is the theoretical basis of weak magnetic detection technology. This theory reveals and explains the change rules of magnetic energy potential of ferromagnetic materials in the weak magnetic state and its quantitative relationship. Based on this theory, TCK established a corresponding mathematical model. Based on the internationally recognized technical standards for steel wire ropes and verified by a large number of technical tests, the quantitative calculation of the effective metal cross-sectional area loss caused by various types of damage to the wire rope based on this mathematical model is accurate and can fully meet the requirements for quantitative detection of internal and external defects in the wire rope. This theory breaks through the long-standing traditional magnetic detection technology principles, realizes a qualitative leap in magnetic detection technology from qualitative detection to quantitative detection, and then completes an accurate, scientific and objective assessment of the remaining load-bearing capacity and service life of the steel wire rope.

       4 Principle of wire rope online detection system

　　The TCK online real-time automatic detection system for steel wire ropes based on weak magnetic technology (see attached picture) uses a reliable structure to install and fix the system detection device at an appropriate position to facilitate the detection of the elevator wire rope. During detection, the weak magnetic loading device first performs weak magnetic planning on the entire length of the steel wire rope; a detection device equipped with a "Dou element" high-sensitivity sensor is installed, and then a "holographic" slice detection is performed on the steel wire rope, and the original detection signal is extracted and output; The data acquisition conversion device (secondary station) of the system receives the original detection signal, and at the same time completes the specified mathematical model and information format conversion, realizes the preliminary processing and information storage of the original data, and transmits the running data through wired or wireless communication transmission methods. The wire rope damage signal is transmitted to the multi-channel main control center (master control station) in real time for comprehensive analysis and calculation, and the detection results are obtained. The detection results are displayed in real time on the display terminal, the detection report is automatically printed, and the archiving of the detection results is completed at the same time [1 ]. In addition, the system is also equipped with an audible and visual alarm system, which can provide real-time alarm prompts for severe injuries found during detection, and initiate emergency treatment measures according to the preset early warning plan to ensure the safe operation of the equipment.

附图 钢丝绳在线自动检测系统工作原理

        5 Application practice of TCK.W steel wire rope online automatic detection system

        Tongmei Group has a total of 40 mine hoists and invests nearly 20 million yuan in wire ropes every year. How to scientifically manage and safely use wire ropes has always been a problem. In December 2010, Tongmei Group installed the TCK wire rope online real-time automatic detection system in the ground hoisting machine rooms of the auxiliary shafts and auxiliary inclined shafts of its 20 mines. It was debugged and put into use that month, replacing the systems used in the past. The new wire rope inspection method realizes the transformation from traditional manual inspection to scientific quantitative inspection. Facts have proven that the TCK wire rope online real-time automatic detection system can improve the automation and effectiveness of wire rope inspections, completely solve the many problems that existed in the past wire rope inspections such as unsafe, uneconomical, low efficiency, unscientific, and high hidden dangers, and improve the utilization of equipment. Rate. After the TCK steel wire rope online real-time automatic detection system was installed in the auxiliary shafts of 20 mines of Tongmei Group, the lifting wire ropes of the auxiliary shafts of each mine are always in a safe and controlled detection state, fundamentally eliminating hidden dangers and ensuring the safe operation of the lifting wire ropes. At the same time, the installation and use of this detection system also saves detection time for the mine and creates considerable economic benefits; it also plays a significant role in reducing detection energy consumption and reducing the amount of steel wire ropes. According to the "Coal Mine Safety Regulations", coal mines must spend at least 1 hour on manual inspection of wire ropes every day. Tongmei Group installed a auxiliary shaft hoist using the TCK wire rope online real-time automatic detection system. Its power is basically 280 to 1000kW. The annual idling energy consumption for wire rope detection in 20 mines is about 1.6 million kW·h; using this detection After the system is installed, all these detection wastes will be saved. In addition, the installation and use of this detection system can promptly understand the safety status of the hoisting wire rope operation and the development and change of damage, so that timely targeted maintenance measures can be taken to slow down the deterioration of the wire rope and achieve the purpose of extending the service life of the hoisting wire rope. . According to statistics, using the TCK wire rope online real-time automatic detection system, coal mines can reduce the consumption of lifting wire ropes by about 1/3 every year because the safe service life of the wire ropes is extended.

    6 Conclusion

　 The TCK wire rope online real-time automatic detection system can realize all-round online automatic detection of wire ropes in major equipment and important facilities, creating a new safety supervision model for wire rope operation for users, eliminating unsafe hidden dangers, reducing labor intensity, and improving work efficiency. This has very important practical and long-term significance for ensuring safe production in coal mines, improving economic benefits, and promoting enterprise development.