基于场均衡优化磁路的钢丝绳缺陷多元件阵列协同检测方法

Detection of the wire rope directly relates to the personal and equipments safety. However, detection of the wire rope is confronted with some problems at present. For example, it is difficult to achieve the desired magnetization, the detection result is affected by the running speed, the detection distance and the environment, the detection accuracy is not high, the versatility is not strong and so on. Therefore, the key technology of wire rope detection-multi-element array collaborative detection methods of wire rope defects based on magnetic field balance optimization need to be studied urgently. The study contents are as followed: (1) The influence of the structure and the parameters of the multi loop structure on the magnetization is studied by means of the three dimensional time domain FDTD optimization and analytical method. The optimal excitation structure model based on field balance is constructed. (2) Find out the effect of the complex structure defects and lift off value on the magnetic field distribution in three-dimensional space, obtain the relationship between the spatial signal with different types, forms and extent of damage, explore to achieve a full range detection method of wire rope with a small amount of magnetic components and optimization of combined magnetic array. (3) Establish the signal preprocessing model of online detection of wire rope, propose feature extraction and recognition algorithms of quantitative defect of singular signal, form a set of wire rope detection forming theory and effective methods, lay the foundation for the development of high reliability testing equipment. The project comes from the national demands as well as being in line with the national development strategy, the target of this topic is a reasonable extension of our long-term researches on metal materials testing. It is of great significance to promote the development of nondestructive testing technology.

钢丝绳运行状况检测关系人身与设备安全。目前面临着难以达到预期磁化效果，检测结果受速度、检测距离及环境影响较大，检测准确性不高、通用性不强等问题。亟需对其关键技术—基于场均衡优化磁路的钢丝绳缺陷多元件阵列协同检测方法展开研究。内容包括：（1）采用三维时域FDTD优化和解析结合解法，研究周向均衡多磁化回路结构及参数尺寸对磁化效果的影响，构建基于场均衡的钢丝绳优化励磁结构模型。（2）找出复杂结构缺陷和提离值对三维空间磁场分布影响规律，获取空域信号与不同类型、形态和程度损伤之间关系，探寻用少量磁敏元件和优化聚磁阵列相结合实现钢丝绳全方位无漏检方法。（3）建立钢丝绳检测信号预处理模型，提出缺陷奇异信号特征提取与定量识别算法，形成一套钢丝绳检测成型理论和有效方法，为高可靠性探伤设备研制奠定基础。课题符合国家发展战略需求，是申请人长期从事金属材料探伤研究的合理延伸，对促进无损检测技术发展具有重要意义。

本项目针对目前钢丝绳检测存在的不足，进行了基于场均衡优化磁路的钢丝绳缺陷多元件阵列协同检测方法研究。内容包括：调研了冀中能源集团、北京京煤集团、甘肃窑街煤电集团煤矿等20多个矿井和辽宁、天津等多处港口、起重机械、索道钢缆的使用、现场运行情况及配套安全检测系统，到钢缆及探伤仪生产企业进行技术交流30余次，查阅各类中英文文献810余篇，专利300余项，完成各种分析测试1960余次。通过对10万余条检测数据的系统梳理和分析，结合大量实验研究，设计出了以磁通平衡为基础的钢缆无损检测模型，探索了面向不同用途钢丝绳缺陷的多元件阵列协同检测方法。建立了多通道信号采集与预处理模型，研究了基于VMD-DWT-AWT的信号降噪方法，提出了基于形态小波支持向量机的缺陷奇异信号特征提取与定量识别算法。并研发形成了1套检测系统，完成了实验室和现场270余处及420万检测点测试数据的分析。已发表了SCI、EI收录等学术论文19篇，申报国家专利6项，出版专著1部；培养了博士1名，硕士6名，指导了20余名本科毕业设计和大学生创新训练，课题参加人员30余人，共投入1000人月。按计划要求完成了申请书及计划书规定的全部内容。项目研究对促进无损检测技术和学科发展进步具有重要意义。