In busy and dynamic ports, steel wire ropes serve as a solid link between supporting heavy objects and lifting equipment, and their safety and stability are the cornerstones to ensure smooth port operations. However, in the face of complex and variable working environment and continuous high load challenges, the wire rope is vulnerable to multiple damage such as broken wire, wear, rust, fatigue, cage strand, deformation, diameter shrinkage, etc. If these potential threats are not discovered and treated in time, they will gradually accumulate until catastrophic fracture accidents.

For a long time, although the safety management of wire rope has received much attention, it is difficult to get rid of the dependence on manual detection, and the hidden danger of wire rope breaking is difficult to eliminate. Now, Luoyang Wire Rope Inspection Technology Co., LTD. (TCK.W) with its independent research and development of "magnetic memory AI weak magnetic non-destructive testing technology", to provide a revolutionary solution to this problem.

The technology not only realizes the intelligent monitoring of the whole life cycle of the rope such as the opposite shore bridge, the trolley traction and the pitching wire rope to achieve accurate early warning, but also replaces the manual detection with machine intelligence, raising the safety monitoring to an unprecedented height. Its application not only ensures the safety and efficiency of port operations, but also shows great potential in energy saving and emission reduction, cost control, equipment utilization rate improvement and enterprise output value growth, and has become an indispensable security guardian of the port industry.

1. The main pain points in wire rope operation can be summarized as follows:

Pain point 1: The use of wire rope is unsafe:： Due to the gradual loss of the strength of the wire rope, it is easy to break the rope, resulting in casualties and property losses. For example, in November 2018, Dubai Ports World announced that due to multiple broken rope accidents, it decided to shorten the hoisting rope replacement cycle from 4,000 hours to 1,400 hours to prevent future accidents.

Pain point two: manual detection of wire rope efficiency is low： Regular manual inspection takes a long time and affects operation efficiency. According to the provisions of the "Steel Wire Rope Inspection, Maintenance and replacement System" of each port, it is necessary to test and maintain according to requirements. For example, the manual inspection of Meishan Port occupies a lot of working time, and the shore bridge needs to stop the lifting work and stop the inspection during the inspection, so the lifting operation is affected, and a lot of time is occupied invisibly.

Pain point 3: The wire rope test results are not reliable： Manual detection is limited by the field of vision, environment and subjective judgment, it is difficult to fully find the internal and external wear, rust, broken wire and other hidden dangers, especially the internal damage is often ignored, many wire rope surface looks good, no visible broken wire, but the internal broken wire, rust has been very serious, resulting in the accuracy of manual detection results greatly reduced.

Pain point four: The cost of rope waste is huge： Due to the uncertainty of manual inspection, the using unit needs to replace the wire rope regularly or quantitatively, regardless of its actual condition. Different port rope standards vary, such as Meishan port lifting rope 8 months a change, and many of the replaced wire rope actual loss is very small, about 70% is not fully used that is replaced.

2. Technological innovation: the birth and advantages of magnetic memory weak magnetic nondestructive testing technology

In the vast starry sky of non-destructive testing technology, TCK.W's "magnetic memory AI weak magnetic non-destructive testing technology" is like a bright pearl, illuminating a new chapter of wire rope testing with its uniqueness and advanced nature. The technology uses the magnetic memory effect generated by ferromagnetic materials when they are stressed or damaged, and realizes the accurate identification of internal and external damage of the wire rope by precisely planning the magnetic field and capturing its changes. Compared with traditional detection methods, such as visual inspection and caliper measurement, this technology has higher sensitivity and accuracy, and can detect more subtle and hidden damage.

Based on the "magnetic memory weak magnetic non-destructive testing technology", TCK.W has built a series of perfect steel wire rope testing equipment matrix, including the TCK.W quay crane rope intelligent detection expert system, TCK.W floating crane rope intelligent monitoring system, and TCK.W ship unpacker rope online monitoring system for the diversified needs of the port industry. Together, these systems provide an efficient, accurate and safe wire rope inspection solution for port operations.

TCK.W not only solved a series of major technical problems such as "remote monitoring of wire rope safety", "real-time alarm of sudden major hidden dangers", "daily assessment of damage status" and "regular assessment of damage development trend"; Moreover, the two processes of production and testing are combined into one, which saves a lot of testing time and energy consumption. Scientific extension of wire rope service life. The promotion and use of TCK.W will have a great effect on the safety, energy saving, cost reduction and efficiency of port enterprises, and can achieve good economic and environmental benefits.

TCK.W's technology offers the following significant advantages:

l  Non-contact inspection: there is no need to contact the surface of the wire rope directly, which avoids secondary damage to the wire rope during the inspection.

l  Real-time online monitoring: Support continuous and uninterrupted 24h*365 days real-time monitoring, to ensure the full control of the state of the wire rope.

l  Detection and production synchronization: complete monitoring at the same time of production, so that production and monitoring are combined into one, so as to effectively improve the utilization rate of equipment.

l  High precision sensor array: The use of high sensitivity sensor array, to achieve fine detection of wire rope.

l  Intelligent early warning system: Through the detection data processing and analysis, can automatically generate damage analysis and early warning information.

l  Real-time data transmission: Supports wired/wireless data transmission, and transmits test data to the cloud or local server for analysis and processing in real time.

l  Data export and sharing: Export and share test data to facilitate subsequent analysis and report compilation.

l  Strong adaptability: It is suitable for wire rope testing in different specifications and different working conditions, and has a wide range of application prospects.

l  Customized solutions and services: According to the characteristics and needs of different port cranes to provide customized inspection solutions, from equipment selection, installation and commissioning to training guidance of a full range of customized services.

3. Application scenarios: deep port every corner of the guard

TCK.W's steel wire rope inspection equipment is widely and deeply applied in the port industry. From the busy quay crane to the vast sea area to the efficient unloader site, they are everywhere to guard the safety and stability of each wire rope.

On the quay crane, the inspection expert system monitors key parts such as the pitch rope, lifting rope and trolley rope around the clock to ensure that they remain in optimal condition during high intensity operations. Once the potential damage is found, the system will immediately send an early warning signal and notify the maintenance personnel to deal with it, effectively avoiding the occurrence of safety accidents.

In the floating crane operation, the intelligent monitoring system provides all-round safety guarantee for the floating crane rope with its excellent detection performance. It can maintain stable detection performance even in rough seas and send data back to the control center in real time for remote monitoring and management.

4. Application effect and future prospect

TCK.W's steel wire rope inspection equipment has achieved remarkable results in the port industry. They not only improve the safety of port operation and reduce the probability of safety accidents; It also helps port enterprises make scientific maintenance plans to reduce rope costs by accurately evaluating the service life and damage degree of rope. At the same time, these intelligent inspection equipment also promotes the green development of port operations, reduces energy consumption and emissions, and contributes to sustainable development.

Looking forward to the future, TCK.W will continue to adhere to the concept of innovation and quality, and continue to optimize and improve the steel wire rope inspection technology to provide more efficient, accurate and intelligent inspection solutions for the port industry. At the same time, TCK.W will also actively explore cooperation with other industries to apply magnetic memory weak magnetic nondestructive testing technology to more fields to promote the comprehensive development and progress of nondestructive testing technology.