As a high risk component of important hoisting, lifting and conveying equipments, wire rope is regarded as the lifeline in many industries. However, its safety has always been a “blind spot” or “source of danger” in equipment management, due to the lack of reliable testing instruments. Therefore, it has been an urgent need for wire rope users to have a scientific instrument which is capable to detect the deterioration state of in-service wire ropes and assure their safe operation.

TCK Wire Rope Online Automatic Inspection System has successfully achieved online automatic monitoring of the safety state of in-service wire ropes. It has made it possible for wire rope users to monitor in real-time the deterioration of in-service wire ropes, reliably prevent accidents caused by rope failures, scientifically reduce wire rope operation costs, and effectively improve wire rope operation efficiency.

This system is capable to detect and evaluate quantitatively various Localized Flaws (LF) (such as broken wire, abrasion, corrosion and fatigue), the Loss of Metallic Cross-Sectional Area (LMA) and rope diameter reduction.  It can count the number of broken wires within one unit of rope length. Thereby, it is capable to correctly evaluate in-service wire rope’s safety status, residual bearing capacity and service life.

 

2.   Specifications of TCK Wire Rope Online Automatic Inspection System

Type	System Model	Testing Head Model	Rope Diameter (mm)	Weight of Testing Head (㎏)	Dimension (mm)
Wire Communication	TCK-YX300	65 model	Φ16-Φ32	1.060	1000*250*180
		85 model	Φ32-Φ56	1.541	1200*270*200
		Customized model	＞Φ56
Wireless Communication	TCK-WX300	65 model	Φ16-Φ32	1.060	1000*250*180
		85 model	Φ32-Φ56	1.541	1200*270*200
		Customized model	＞Φ56

 

3.   Technical Parameters of TCK Wire Rope Online Automatic Inspection System

1)     Sensor sensitivity: Amax = 5 A/G and adjustable sensitivity vlaue A = 2.6 V/G-5V/mT

2)     Rope speed Vmax = 30 m/sec; Safety rope speed V = 0-13 m/sec

3)     Quantitative inspection accuracy: Pmax = 5‰

4)     Quantitative inspection uncertainty P < 1%

5)     Real-time detectability and evaluation accuracy for different types of flaws:

a)     For minor defects: detectability > 85%; Evaluating accuracy > 90%

b)     For normal defects: detectability>95%; Evaluating accuracy > 90%

c)     For dangerous defects: detectability=100%; Evaluating accuracy> 95%

d)     For limiting defects: detectability=100%; Evaluating accuracy>95%