基于聚磁原理的钢丝绳断丝无损检测方法

doi:10.3901/JME.260037

摘要/Abstract

摘要： 服役钢丝绳断丝呈现空间复杂螺旋分布及空间断丝位置相邻很近等特征，钢丝绳断丝检测难度大和准确性低。因此，开展基于聚磁技术和三维漏磁检测的钢丝绳断丝无损检测研究，对提高钢丝绳断丝检测准确性和保障钢丝绳承载安全性具有重要意义。基于Maxwell有限元软件和试验平台开展了钢丝绳不同断丝模式下(断口长度、断丝数量、断丝位置)漏磁场有限元分析和断丝检测试验，揭示了聚磁装置对钢丝绳断丝漏磁场变化规律以及钢丝绳不同断丝模式下漏磁信号特征演化规律。结果表明：聚磁装置对钢丝绳断丝漏磁检测具有增益效果，且磁导凸台中心处漏磁信号变化最为显著；钢丝绳断丝三维漏磁检测信号与钢丝绳断丝特征(断口长度、断丝数量)呈正相关，钢丝绳断丝特征变化越大，漏磁信号变化越显著；不同方向漏磁分量对钢丝绳断丝特征敏感程度大小关系如下：轴向分量>径向分量>周向分量；钢丝绳内部与外部存在相同断丝数时，外部断丝时信号变化更显著；钢丝绳出现轴向邻近断丝时，邻近断丝时漏磁场发生叠加，其三轴漏磁分量均有显著增加(较于单根断丝)；钢丝绳出现周向多处断丝时，断丝距磁导凸台越近，断丝信号变化越显著。

关键词: 钢丝绳, 断丝, 聚磁技术, 三维漏磁检测

Abstract: The broken wire of wire rope in service presents the characteristics of complex spiral distribution in space and close proximity in space, which makes the detection of wire rope broken wire difficult and low in accuracy. Therefore, the research on non-destructive testing of wire rope breakage based on magnetic aggregation technology and three-dimensional magnetic flux leakage testing(MFT) is of great significance to improve the accuracy of wire rope breakage detection and ensure the safety of wire rope bearing. Based on the 3D MFT principle and magnetic aggregation technology, Maxwell finite element software and test platform were used to carry out finite element analysis of magnetic flux leakage(MFL) field and detection test of broken wire under different wire breaking modes(broken length, broken number and broken position). The variation law of MFL field on wire rope breaking by magnetic aggregation concentrator and the evolution law of MFL signal characteristics under different wire rope breaking modes are revealed. The results show that the magnetic aggregation concentrator has a gain effect on the magnetic flux leakage detection of wire rope broken wires, and the change of the magnetic flux leakage signal at the center of the aggregation concentrator is the most significant.; There is a positive correlation between the 3D MFL signal of wire rope breaking and the characteristics of wire rope breaking(length of wire break, number of wire break). The greater the change of wire rope breaking characteristics, the more significant the change of MFL signal. The sensitivity of MFL components in different directions to the wire rope breaking characteristics is as follows: axial component > radial component > circumferential component; When there is the same number of broken wire inside and outside the wire rope, the signal change is more significant when the wire is broken outside the wire rope. The MFL field is superimposed when the wire rope is adjacent to the broken wire, and the 3D MFL field components increase significantly(compared with that of a single broken wire). When the wire rope is broken at multiple circumferential places, the closer the broken wire is to the permeability boss, the more significant the change of broken wire signal is.

Key words: wire rope, break, magnetic aggregation technology, three-dimensional magnetic flux leakage signal

中图分类号:

TH117

孙远, 王大刚, 张德坤, 李陈晨, 汤梁. 基于聚磁原理的钢丝绳断丝无损检测方法[J]. 机械工程学报, 2026, 62(2): 61-72.

SUN Yuan, WANG Dagang, ZHANG Dekun, LI Chenchen, TANG Liang. Nondestructive Testing of Wire Rope Breakage Based on Magnetic Aggregation Technology[J]. Journal of Mechanical Engineering, 2026, 62(2): 61-72.

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