Nondestructive Testing of Wire Rope Breakage Based on Magnetic Aggregation Technology

doi:10.3901/JME.260037

Abstract

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

CLC Number:

TH117

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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