The wire rope magnetic flaw detection technology listed in the "National Key Technologies for Prevention and Control of Major Work Safety Accidents".
The wire rope magnetic flaw detection technology awarded the "China Machinery Industry Science and Technology Award".
The patented "magnetic balance detection technology" does not require deep magnetization of the wire rope and features a simple structure.
It has high broken wire detection sensitivity (0.5% of the wire rope's cross-sectional area).
It overcomes the impact of wire rope shaking on measurement, and can detect both internal and external broken wires.
Mine hoists are large-scale lifting machinery and equipment. Driven by an electric motor, they operate mechanical components to drive steel wire ropes, which in turn lift or lower containers within the shaft to fulfill transportation tasks. Based on the connection mode of the steel wire ropes on the drum, they are classified into winding hoists and friction hoists. According to the number of hoisting ropes, they can be divided into two-rope, four-rope, and six-rope hoists. This product employs the patented "magnetic balance" detection technology to achieve comprehensive safety monitoring of hoist steel wire ropes. Through real-time online monitoring of defects such as broken wires, deformation, wear, and corrosion, it scientifically prevents rope breakage, thereby reducing maintenance costs and saving on rope replacement expenses.
Real-time monitoring of the safety status of steel wire ropes, scientifically preventing rope breakage accidents and ensuring safety.
Realizing the automation of daily steel wire rope detection to improve enterprise production efficiency.
Assisting enterprises in eliminating safety hazards in steel wire rope operation and achieving safe production.
Scientifically reducing the rope usage cost of enterprises, improving the utilization rate of steel wire ropes, and avoiding unnecessary rope replacement.
System Composition
Intrinsically Safe Sensor Group: Integrates multiple flaw detection sensors, a non-contact speed sensor, and a 32-bit ARM microcontroller for data acquisition.
① The sensors detect defects in the steel wire rope, convert them into analog signals, and output these signals to the 32-bit ARM microcontroller. The microcontroller performs analog-to-digital conversion and signal processing, then converts the useful signals into CAN bus signals for transmission.
② The non-contact speed sensor picks up the strand peak signals of the steel wire rope, converts them into pulse signals, and outputs these to the ARM microcontroller for positioning information.
Mine-used Flameproof and Intrinsically Safe Substation: Comprises an intrinsically safe power supply, a servo microcontroller, and a data acquisition communication module.
① The intrinsically safe power supply (12V/2A) powers both the sensor group and the microcontroller.
② The servo microcontroller controls the main power supply (on/off) or stops the operation of the steel wire rope according to commands from the host computer.
③ The data acquisition and communication module receives signals from multiple sensor groups, processes and packages the data, then transmits it to the host computer.
Surface-output Intrinsically Safe Information Transmission Interface: Consists of an intrinsically safe power supply and a CAN communication data conversion interface, functioning as a safety barrier.
① The intrinsically safe power supply powers the CAN communication data conversion interface.
② The communication data conversion interface converts CAN signals into USB interface signals for transmission to a computer.
Industrial Control Computer Station: Comprises a dedicated cabinet, industrial control computer, specialized steel wire rope data processing software, printer, SMS notification module, etc. Its functions include data acquisition and processing, graphical display, data storage, defect type analysis and judgment, generation and printing of detection reports, and SMS notifications to clients.
Product Overvie
Kewei is committed to continuous transcendence and innovation. In addition to the following basic functions, our products can also achieve more personalized functions according to customer requirements.
Based on the magnetic flux balance detection principle for metallic material defects and dedicated sensors, it completely eliminates the impact of wire rope shaking on measurement. It can detect both external and internal broken wires, and measure the movement direction of the wire rope.
Realizes online real-time monitoring and precise positioning of wire rope defects, including broken wires, deformation, wear, corrosion, strand loosening, and wire skipping.
Accurately measures internal broken wires and those at strand valleys (valley broken wires may indicate internal damage). The broken wire detection sensitivity reaches 0.5% of the wire rope's cross-sectional area (LF), and the LMA detection sensitivity is 1%. It can accumulate the cross-sectional area of broken wires within one lay length and compare it with the total wire cross-sectional area.
Both the speed sensor and flaw detection sensor use non-contact induction with the wire rope, ensuring safety and efficiency.
When two or more valley broken wires are detected within one lay length, the system automatically alarms, complying with GB/T 5972-2009 Crane Wire Rope Maintenance, Installation, Maintenance, Inspection, and Discard Standard 3.5.2 – wire ropes should be considered for discard under such conditions.
Accumulatively assesses the degree of single-item local damage to the wire rope and comprehensively evaluates the remaining bearing capacity.
All detected defects can be located via computer software control. After setting a search target, the system automatically stops the wire rope when the defect passes through the sensor, allowing users to find the defect within 100mm from the sensor outlet for further inspection or repair.
Alarm information and detection reports can be printed and sent via SMS.
During remote operation, the system powers on automatically when the software runs and powers off when the software stops.
Enables review, photography, and comparison of historical data for intuitive visualization of wire rope condition changes.
The software interface can display detection curves of multiple wire ropes simultaneously for clear oversight.
The system can cut off the motor power to stop the wire rope when severe damage is detected, ensuring production safety as needed.
Automatically prompts fault information when issues occur in sensors, microcontrollers, interfaces, or transmission cables.
Facilitates strict control of the overall wire rope operation status.
Kewei assists users in remotely monitoring wire rope operation and provides monitoring reports in a user-friendly manner.
Sensors feature fully stainless steel seamless housings for protection against water, dust, and vibration.
Reports include key information such as defect locations, defect percentage, wire rope strength reduction percentage, and remaining service life – addressing users' primary concerns.
Supports Windows XP, Windows 7, etc.
Technology lnnovation
Adopting Canadian technology, a patented product.
The sensor technology applies the invention patent - magnetic flux balance measurement principle. It features high measurement sensitivity, overcomes the impact of wire rope shaking on measurement accuracy, and can effectively detect both internal and external broken wires in the wire rope.
Equipped with strong anti-interference circuits and relevant measures, it can effectively overcome various interferences such as wireless electromagnetic field interference, power supply pollution, and mechanical vibration.
High sensor sensitivity: The sensitivity for detecting broken wires is 0.5% of the wire rope's cross-sectional area.
Achieves a true DC amplifier, where the size of the sensor output signal is independent of the wire rope's movement speed.
Can measure the movement direction of the wire rope, i.e., whether the wire rope is rotating forward or reverse.
Realizes non-contact measurement technology for the movement speed of the wire rope.
Multi-sensor unit detection solves the blind zone problem in wire rope measurement.
Innovative application of the Internet of Things (IoT) concept. Our company establishes a service center for customers through the IoT to achieve remote data operation (via the Internet or SIM card) and remote user services: regularly detecting the damage status of the wire rope and the operating status of the detection equipment for users every day, and presenting detailed detection reports to users via SMS, email, or fax.
TechnicalSpecification
Software Lnterface
Measurement GraphDescription
