新型钢丝绳探伤仪的设计与研究
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摘要
钢丝绳作为牵引、承载的重要部件被广泛应用于煤炭、冶金、船舶等行业,其运行状态直接关系到了设备的安全,一旦发生事故,后果将是严重的。而目前的钢丝绳检测方法和检测装置还存在很大不足。基于强磁检测技术的检测精度不高,受速度影响较大;探伤仪结构相对复杂,磁化与检测不同步;以单片机为控制系统,系统性能较低。因此,本文基于弱磁检测技术,设计研制了新型钢丝绳探伤仪。论文主要完成了以下工作:
首先,本文分析了钢丝绳的结构与检测原理,提出了弱磁无损检测。对新型探伤仪的磁化单元与检测传感器进行了设计与布置。利用弱磁传感器作为探伤传感器,以磁场矢量综合原理进行探伤。
其次,基于模块化设计方法对探伤仪的结构进行了功能分析与模块划分,得出4个功能模块。利用Pro/E软件对各分模块进行了建模与装配。将弱磁加载器与损伤检测器设计为一个整体,打破了传统分为两个步骤探伤的局面。同时,对探伤仪导向轮系进行了有限元动力学分析,分析确定了导向轮与支承轴在翘丝碰撞时的最大应力与变形,确保产品结构设计的可行性。
接着,根据当前钢丝绳在线检测的需要,本文设计了基于ARM7微处理器的探伤系统。系统的核心采用了飞利浦公司的ARM7TDMI内核的LPC2368芯片,系统硬件包括信号调理、A/D转换器、键盘输入、液晶显示与USB接口,可实现单独实时检测也可以同PC机相连分析检测结果。
最后,本文利用制造的探伤仪样机进行了探伤仪的结构与检测系统实验。
实验证明,基于弱磁检测技术设计研制的新型钢丝绳探伤仪可以实现对钢丝绳损伤的弱磁检测,检测的结果与钢丝绳实际损伤较为符合。本文的研究工作也为相关领域的弱磁检测技术的应用提供了有益的参考。
Steel wire ropes as an important part of traction and load are widely used in the coal, metallurgy, and marine industry. The condition of them is related to the safety of the equipment directly. It will be the terrible result once the accident happened. At present, the detection methods and systems for steel wire ropes have some disadvantages. High magnetic detection has not enough testing accuracy, and is largely affected by the detecting speed. The structure of the detector is complicated, and the magnetization and defect detection are not synchronized; many detectors use singlechip as control system, which has lower performance. Therefore, based on the technology of weak magnetic detection, a new defect detector for wire ropes was designed in this paper. The main contents and results of research are as follows:
Firstly, non-destructive weak magnetic testing technology was proposed through analyzing the structure of wire ropes and non-destructive testing principle. The magnetization module and sensor were designed. The weak magnetic sensor was selected as detection sensor and the vector synthesis of magnetic field was used to detect.
Secondly, based on the modular design method, the overall structure of the detector was analyzed and divided into four function modules. The model of each function part was established and assembled into a whole module by means of Pro/E software. The weak magnetic magnetization and defect detection are designed as a whole, breaking the traditional two-step testing situation. Then, the finite element dynamic analysis was used to analyze the guide rollers to ensure the product structure design is reliable.
Next, according to the need of the on-line detection, tthe detection system was designed based on the ARM7 microprocessor. The key part of the system uses LPC2368 chip of the Philips ARM7 TDMI. Hardwares of the system include signal conditioning, A / D converter, keyboard input, liquid crystal display and USB interface. The system can carry on real-time detection alone using communication interface, and also can connect with the PC to analyze the testing results.
At last, lots of experiments have been done to test the system and structure of the defect detector for wire ropes.
Experiment results show that the new type defect detector can detect different kinds of defaults of wire ropes by means of weak magnetic detecting technology. The detecting results are in accordance with the actual damage of wire ropes basically. The studys provide a useful reference for the application of weak magnetic detecting in other relative fields.
首先,本文分析了钢丝绳的结构与检测原理,提出了弱磁无损检测。对新型探伤仪的磁化单元与检测传感器进行了设计与布置。利用弱磁传感器作为探伤传感器,以磁场矢量综合原理进行探伤。
其次,基于模块化设计方法对探伤仪的结构进行了功能分析与模块划分,得出4个功能模块。利用Pro/E软件对各分模块进行了建模与装配。将弱磁加载器与损伤检测器设计为一个整体,打破了传统分为两个步骤探伤的局面。同时,对探伤仪导向轮系进行了有限元动力学分析,分析确定了导向轮与支承轴在翘丝碰撞时的最大应力与变形,确保产品结构设计的可行性。
接着,根据当前钢丝绳在线检测的需要,本文设计了基于ARM7微处理器的探伤系统。系统的核心采用了飞利浦公司的ARM7TDMI内核的LPC2368芯片,系统硬件包括信号调理、A/D转换器、键盘输入、液晶显示与USB接口,可实现单独实时检测也可以同PC机相连分析检测结果。
最后,本文利用制造的探伤仪样机进行了探伤仪的结构与检测系统实验。
实验证明,基于弱磁检测技术设计研制的新型钢丝绳探伤仪可以实现对钢丝绳损伤的弱磁检测,检测的结果与钢丝绳实际损伤较为符合。本文的研究工作也为相关领域的弱磁检测技术的应用提供了有益的参考。
Steel wire ropes as an important part of traction and load are widely used in the coal, metallurgy, and marine industry. The condition of them is related to the safety of the equipment directly. It will be the terrible result once the accident happened. At present, the detection methods and systems for steel wire ropes have some disadvantages. High magnetic detection has not enough testing accuracy, and is largely affected by the detecting speed. The structure of the detector is complicated, and the magnetization and defect detection are not synchronized; many detectors use singlechip as control system, which has lower performance. Therefore, based on the technology of weak magnetic detection, a new defect detector for wire ropes was designed in this paper. The main contents and results of research are as follows:
Firstly, non-destructive weak magnetic testing technology was proposed through analyzing the structure of wire ropes and non-destructive testing principle. The magnetization module and sensor were designed. The weak magnetic sensor was selected as detection sensor and the vector synthesis of magnetic field was used to detect.
Secondly, based on the modular design method, the overall structure of the detector was analyzed and divided into four function modules. The model of each function part was established and assembled into a whole module by means of Pro/E software. The weak magnetic magnetization and defect detection are designed as a whole, breaking the traditional two-step testing situation. Then, the finite element dynamic analysis was used to analyze the guide rollers to ensure the product structure design is reliable.
Next, according to the need of the on-line detection, tthe detection system was designed based on the ARM7 microprocessor. The key part of the system uses LPC2368 chip of the Philips ARM7 TDMI. Hardwares of the system include signal conditioning, A / D converter, keyboard input, liquid crystal display and USB interface. The system can carry on real-time detection alone using communication interface, and also can connect with the PC to analyze the testing results.
At last, lots of experiments have been done to test the system and structure of the defect detector for wire ropes.
Experiment results show that the new type defect detector can detect different kinds of defaults of wire ropes by means of weak magnetic detecting technology. The detecting results are in accordance with the actual damage of wire ropes basically. The studys provide a useful reference for the application of weak magnetic detecting in other relative fields.
引文
[1]钟永棋.港口起重机钢丝绳断裂事故分析及预防措施[J].起重运输机械,1993, 32(4): 30-32.
[2]曹印妮,张东来,徐殿国.钢丝绳定量无损检测现状[J].无损检测,2005,27(2):91-95.
[3]杨利军,张孟姝.基于弱磁原理TCK钢丝绳检测技术在港口机械上的应用展望[J].矿山机械,2004,(9):38-39..
[4]华文渊.钢丝绳的选用与报废标准[J].起重运输机械,1981, (3) :73-77
[5]吴宾义译.ISO/DIS4309(ISO/TC96)起重机构钢丝绳的检查方法和报废标准[J].起重运输机械,1981, (5):: 75-81.
[6]武新军.钢丝绳截面积损失的磁性无损检测原理与技术[J].武汉:华中科技大学图书馆,1999.
[7] Corden H H.A Review of Wire Rope NDT(Part I ) [M].Wire Industry, 1989,56(9):583-586.
[8] Geller L B and Udd J E. NDT of Wire Ropes with E/M Inspection[J]. CIM Bulletin, 1992,85(964): 60-70.
[9] Bundy S A H. Eddy Current Testing of Wire and Bar[J]. Wire Industry,1981, 48(576):887- 888.
[10] Dziobek S.How Safe is a Rape[J].Internationale Seilbahn-Rundschau,l982,(5):287-294.
[11] Haller A.New Methods of Measuring the Cross-Sections of Ropes[J].Intemationale, Seilbahn-Rundschau,1984,(3):121-124.
[12] Cacciatore V,Canova A,Vallan A.Experience and technologier in NDT of ropes[J].Key Engineering Materials,2007,347:627-632.
[13] Phillip J,Rao C.B.A new optical techniques for detection of defects in ferromagnetic material and components[J]. NDT&E International,2000,33:289-395.
[14] Steven K.J. Stress dependence of ferromagnetic hystersis loops for two grades of steel [J]. NDT&E International,2000,33:111-121.
[15] Chen K, Branan F.P,Dover W.D.Thin-skin AC field in anisotropic rectangular bar and ACPD stress measurement[J]. NDT&E International,2000,33:317-323.
[16] Dolemon C.The Safely of Ropeways in France and the Recent Accident[J].International Seilbahn—Rundschao,1987,(3):133-136.
[17] E.Kalwa,Piekarski K.fundamental of Magnetic Testing of Steel Ropes[J].C.S.NDTjournal,1987,8(2):36-43.
[18] E.Kalwa, Piekarski K.qualitative and quantitative Determination of densely occurring defects in Steel Ropes by magnetic testing method[J].Material evaluation,1988,46(5):767-770.
[19] E.Kalwa, Piekarski K.Determination of flaws located at different depth levels in the cross- section of Steel Ropes[J].NET&E International,1987,21(2):77-82.
[20] E.Kalwa, Piekarski K.Design of Inductive Sensors for Magnetic Testing of Steel Ropes[J].NET International,1987,20(6):347-353.
[21]邬述晖.钢丝绳金属截面积损失捡测系统研究[[D].武汉理工大学硕士论文,2004, 4.
[22] Weischedel H R. The Inspection of Wire Ropes in Service[J]. Wire Journal International, 1985, 9: 180-198.
[23] Weischedel H R. Electromagnetic Wire Rope Inspection in Germany 1925-40[J]. Materials Evaluation,1988, 46(6): 734-736.
[24] Weischedel H R. Ramsey R P. Electromagnetic Testing: a Reliable Method for the Inspection of Wire Rope in Service[J]. 1989, 22(3): 155 -161.
[25] Weischedel H R. Wire Rope Strength Estimates, Retirement Critical and Electromagnetic Inspection-A Critical Review[J]. Wire Rope News&Sling Technology,1993, 12: 14-17
[26]康宜华,武新军,杨叔子.磁性无损检测技术中的磁化技术[J].无损检测,1999, 21(5) :206-209.
[27]康宜华,,杨克冲,杨叔子,等.基于钢丝绳结构特征的断丝漏磁霍尔效应检测方法[J].华中理工大学学报,1992,(增刊):188-194.
[28]纪玉波,张岐山.基于微机处理器的钢丝绳断丝损伤检测方法[J].微机与应用,1999,(4):23-24.
[29]纪玉波,张岐山,韩连生.钢丝绳探伤的信号的检测及处理电路[J]..工业仪表与自动化装置,2001,(2):42-43.
[30]赵新民.智能仪器设计基础[M].哈尔滨:哈尔滨理工大学出版社.1999.
[31] Sao N I. Non-destructive Evaluation of Steel Wire Rope (partIII) [M]. Wire Industry. 1996,63(5): 382-390.
[32]贾延林.模块化设计[M].北京:机械工业出版社,1993.
[33]李梦群.先进制造技术导论[M].北京:国防工业出版社,2005.
[34]李永.嵌入式系统的发展现状和发展趋势[J].电脑知识与技术,2005, (3):68-69.
[35]金砺.面向21世纪的嵌入式计算机系统及应用[J].太原师范学院学报(自然科学版),2004,3(2):46-49.
[36]涂有瑞.半导体磁场传感器[J].传感器世界,2003,(7):1-10.
[37]谈兵,杜润生.大直径钢丝绳轴向励磁磁路的研究[J].华中理工大学学报,1994,22(7):36-39.
[38]李高山,张晓东,高海勇,等.MD-2型钢丝绳探伤仪探头的设计和应用[J].矿山机械,2005,(10):13-134.
[39]美国无损检测学会..美国无损检测手册(电磁卷)[M].上海:世界图书出版公司,1999.
[40]窦毓棠,杨旭.TCK钢丝绳损伤定量检测系统基础理论研究[J].矿山机械,2000,(4):37-45.
[41]窦毓棠,杨旭.钢丝绳(缆)全息定量无损检测[J].矿山机械,2000,(5):49-53.
[42]杨叔子,康宜华.钢丝绳断裂定量检测原理与技术[M].北京:国防工业出版社, 1995.
[43]石家宏.模块化设计研讨.船舶设计通讯,1995,(4):21-22.
[44]田军.钢丝绳断丝损伤磁检测原理与技术的研究[D].青岛理工大学硕士论文,2006, 4.
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[47]曾攀.有限元分析及应用[M].北京:清华大学出版社,2004.
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[2]曹印妮,张东来,徐殿国.钢丝绳定量无损检测现状[J].无损检测,2005,27(2):91-95.
[3]杨利军,张孟姝.基于弱磁原理TCK钢丝绳检测技术在港口机械上的应用展望[J].矿山机械,2004,(9):38-39..
[4]华文渊.钢丝绳的选用与报废标准[J].起重运输机械,1981, (3) :73-77
[5]吴宾义译.ISO/DIS4309(ISO/TC96)起重机构钢丝绳的检查方法和报废标准[J].起重运输机械,1981, (5):: 75-81.
[6]武新军.钢丝绳截面积损失的磁性无损检测原理与技术[J].武汉:华中科技大学图书馆,1999.
[7] Corden H H.A Review of Wire Rope NDT(Part I ) [M].Wire Industry, 1989,56(9):583-586.
[8] Geller L B and Udd J E. NDT of Wire Ropes with E/M Inspection[J]. CIM Bulletin, 1992,85(964): 60-70.
[9] Bundy S A H. Eddy Current Testing of Wire and Bar[J]. Wire Industry,1981, 48(576):887- 888.
[10] Dziobek S.How Safe is a Rape[J].Internationale Seilbahn-Rundschau,l982,(5):287-294.
[11] Haller A.New Methods of Measuring the Cross-Sections of Ropes[J].Intemationale, Seilbahn-Rundschau,1984,(3):121-124.
[12] Cacciatore V,Canova A,Vallan A.Experience and technologier in NDT of ropes[J].Key Engineering Materials,2007,347:627-632.
[13] Phillip J,Rao C.B.A new optical techniques for detection of defects in ferromagnetic material and components[J]. NDT&E International,2000,33:289-395.
[14] Steven K.J. Stress dependence of ferromagnetic hystersis loops for two grades of steel [J]. NDT&E International,2000,33:111-121.
[15] Chen K, Branan F.P,Dover W.D.Thin-skin AC field in anisotropic rectangular bar and ACPD stress measurement[J]. NDT&E International,2000,33:317-323.
[16] Dolemon C.The Safely of Ropeways in France and the Recent Accident[J].International Seilbahn—Rundschao,1987,(3):133-136.
[17] E.Kalwa,Piekarski K.fundamental of Magnetic Testing of Steel Ropes[J].C.S.NDTjournal,1987,8(2):36-43.
[18] E.Kalwa, Piekarski K.qualitative and quantitative Determination of densely occurring defects in Steel Ropes by magnetic testing method[J].Material evaluation,1988,46(5):767-770.
[19] E.Kalwa, Piekarski K.Determination of flaws located at different depth levels in the cross- section of Steel Ropes[J].NET&E International,1987,21(2):77-82.
[20] E.Kalwa, Piekarski K.Design of Inductive Sensors for Magnetic Testing of Steel Ropes[J].NET International,1987,20(6):347-353.
[21]邬述晖.钢丝绳金属截面积损失捡测系统研究[[D].武汉理工大学硕士论文,2004, 4.
[22] Weischedel H R. The Inspection of Wire Ropes in Service[J]. Wire Journal International, 1985, 9: 180-198.
[23] Weischedel H R. Electromagnetic Wire Rope Inspection in Germany 1925-40[J]. Materials Evaluation,1988, 46(6): 734-736.
[24] Weischedel H R. Ramsey R P. Electromagnetic Testing: a Reliable Method for the Inspection of Wire Rope in Service[J]. 1989, 22(3): 155 -161.
[25] Weischedel H R. Wire Rope Strength Estimates, Retirement Critical and Electromagnetic Inspection-A Critical Review[J]. Wire Rope News&Sling Technology,1993, 12: 14-17
[26]康宜华,武新军,杨叔子.磁性无损检测技术中的磁化技术[J].无损检测,1999, 21(5) :206-209.
[27]康宜华,,杨克冲,杨叔子,等.基于钢丝绳结构特征的断丝漏磁霍尔效应检测方法[J].华中理工大学学报,1992,(增刊):188-194.
[28]纪玉波,张岐山.基于微机处理器的钢丝绳断丝损伤检测方法[J].微机与应用,1999,(4):23-24.
[29]纪玉波,张岐山,韩连生.钢丝绳探伤的信号的检测及处理电路[J]..工业仪表与自动化装置,2001,(2):42-43.
[30]赵新民.智能仪器设计基础[M].哈尔滨:哈尔滨理工大学出版社.1999.
[31] Sao N I. Non-destructive Evaluation of Steel Wire Rope (partIII) [M]. Wire Industry. 1996,63(5): 382-390.
[32]贾延林.模块化设计[M].北京:机械工业出版社,1993.
[33]李梦群.先进制造技术导论[M].北京:国防工业出版社,2005.
[34]李永.嵌入式系统的发展现状和发展趋势[J].电脑知识与技术,2005, (3):68-69.
[35]金砺.面向21世纪的嵌入式计算机系统及应用[J].太原师范学院学报(自然科学版),2004,3(2):46-49.
[36]涂有瑞.半导体磁场传感器[J].传感器世界,2003,(7):1-10.
[37]谈兵,杜润生.大直径钢丝绳轴向励磁磁路的研究[J].华中理工大学学报,1994,22(7):36-39.
[38]李高山,张晓东,高海勇,等.MD-2型钢丝绳探伤仪探头的设计和应用[J].矿山机械,2005,(10):13-134.
[39]美国无损检测学会..美国无损检测手册(电磁卷)[M].上海:世界图书出版公司,1999.
[40]窦毓棠,杨旭.TCK钢丝绳损伤定量检测系统基础理论研究[J].矿山机械,2000,(4):37-45.
[41]窦毓棠,杨旭.钢丝绳(缆)全息定量无损检测[J].矿山机械,2000,(5):49-53.
[42]杨叔子,康宜华.钢丝绳断裂定量检测原理与技术[M].北京:国防工业出版社, 1995.
[43]石家宏.模块化设计研讨.船舶设计通讯,1995,(4):21-22.
[44]田军.钢丝绳断丝损伤磁检测原理与技术的研究[D].青岛理工大学硕士论文,2006, 4.
[45]宋勇,艾宴清.精通ANSYS7.0有限元分析[M].北京:清华大学出版社,2004,40-46.
[46]龚曙光.ANSYS工程应用实例解析[M].北京:机械工业出版社,2003,50-53.
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