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一种基于磁聚焦原理的钢丝绳断丝检测传感器。

A Sensor for Broken Wire Detection of Steel Wire Ropes Based on the Magnetic Concentrating Principle.

作者信息

Zhang Yiqing, Jing Luyang, Xu Weixiao, Zhan Weixia, Tan Jiwen

机构信息

College of Mechanical and Automotive Engineering, Qingdao University of Technology, Qingdao 266520, China.

出版信息

Sensors (Basel). 2019 Aug 30;19(17):3763. doi: 10.3390/s19173763.

DOI:10.3390/s19173763
PMID:31480374
原文链接:https://pmc.ncbi.nlm.nih.gov/articles/PMC6749426/
Abstract

Electromagnetic testing is the most widely used technique for the inspection of steel wire ropes. As one of the electromagnetic detecting approaches, the magnetic flux leakage (MFL) method has the best effect for the detection of broken wires. However, existing sensors based on MFL method still have some problems. (1) The size of the permanent magnet exciter is usually designed according to experience or rough calculation, and there is not enough depth analysis for its excitation performance; (2) Since the detectable angular range for a single Hall component is limited, Hall sensor arrays are often employed in the design of MFL sensors, which will increase the complexity of the subsequent signal processing due to the extensive use of Hall components; (3) Although the new magneto-resistance sensor has higher sensitivity, it is difficult to be applied in practice because of the requirement of the micron-level lift-off. To solve these problems, a sensor for the detection of broken wires of steel wire ropes based on the principle of magnetic concentration is developed. A circumferential multi-circuit permanent magnet exciter (CMPME) is employed to magnetize the wire rope to saturation. The traditional Hall sensor array is replaced by a magnetic concentrator to collect MFL. The structural parameters of the CMPME are optimized and the performance of the magnetic concentrator is analyzed by the finite element method. Finally, the effectiveness of the designed sensor is verified by wire breaking experiment. 1-5 external broken wires, handcrafted on the wire rope with a diameter of 24 mm, can be clearly identified, which shows great potential for the inspection of steel wire ropes.

摘要

电磁检测是钢丝绳检测中应用最广泛的技术。作为电磁检测方法之一，漏磁（MFL）法在断丝检测方面效果最佳。然而，现有的基于MFL法的传感器仍存在一些问题。（1）永磁激励器的尺寸通常根据经验或粗略计算来设计，对其励磁性能缺乏深入分析；（2）由于单个霍尔元件的可检测角度范围有限，MFL传感器设计中常采用霍尔传感器阵列，这会因大量使用霍尔元件而增加后续信号处理的复杂性；（3）尽管新型磁阻传感器具有更高的灵敏度，但由于对微米级提离的要求，难以在实际中应用。为解决这些问题，开发了一种基于磁聚焦原理的钢丝绳断丝检测传感器。采用圆周多回路永磁激励器（CMPME）将钢丝绳磁化至饱和。用磁聚焦器代替传统的霍尔传感器阵列来采集漏磁。对CMPME的结构参数进行了优化，并通过有限元方法分析了磁聚焦器的性能。最后，通过断丝实验验证了所设计传感器的有效性。在直径为24mm的钢丝绳上手工制作的1 - 5根外部断丝能够被清晰识别，这表明该传感器在钢丝绳检测方面具有巨大潜力。

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