Abstract.: From the viewpoint of modern coal mine construction, the necessity and feasibility of applying TCK weak magnetic steel wire rope detection technology to monitor the safety of steel wire rope are expounded, and the modern mode of steel wire rope safety supervision is explored and practiced.

Subject term：Enhance wire rope detection, weak magnetic detection technology, wire rope online automatic detection, wire rope safety supervision mode

Chinese library classification number：TD532

Document identifier：B

Article number：1003-496X(2011)01-0148-02

With the deepening of modern coal mine construction, most state-owned coal mine enterprises in our country are creating digital and information mines in order to realize the essential safety of coal mine. However, the safety management of mine transportation and lifting equipment still stays in the traditional management stage, which is incompatible with modern coal mine management, and it is urgent to apply advanced modern management means to completely change this backward status quo.

1 Modern coal mine lifting transportation equipment rope management calls for advanced detection technology

The elevator plays a very important role in coal mine production, and the transportation and lifting of operators, raw coal and materials are completed by it. In the lifting transportation, the wire rope maintains the life safety of the workers, is directly related to the safety of mine equipment and property, and is the "lifeline" of the mine "throat". Therefore, lifting steel wire rope is the key and difficult point of mine mechanical and electrical equipment management.

In Tongmei Group, although the safe operation of lifting steel wire rope has been paid much attention, due to the lack of reliable detection means, Tongmei still uses artificial appearance inspection methods and regular rope change measures to ensure the safe operation of lifting steel wire rope for a long time. This backward and unreliable method makes the use of steel wire rope management always exist "five difficult problems".

(1)Unsafe.According to the statistics of "China Coal Mine Accidents and Expert Comments", as of 1995, there were 19,871 deaths in coal mine transportation accidents in China, accounting for 15.06% of the total number of deaths, second only to roof and gas accidents, which is the third largest disaster accident in the coal system. Wire rope has thus become a highly dangerous component in all kinds of transportation and lifting equipment in coal mining enterprises.

(2)Diseconomy. In order to avoid wire rope accidents, wire rope enterprises generally adopt regular replacement measures. This practice of replacing the new rope when it expires has led to an increase in the cost of wire rope. Japan has statistical results that show that more than half of the steel wire rope that is forced to be replaced has a strength of more than 90% of the new rope strength, and many more than 100%, that is, it is still in the run-in period. Survey results in the United States: about 70% of the wire ropes that are forcibly replaced have little or no loss of strength.

(3)Low efficiency.Manual inspection is inefficient and wastes a lot of production time. Taking coal mining as an example, according to the requirements of the "Coal mine safety production regulations", each shift needs to check the wire rope once, each check is about 1 hour, each operation mine only one wire rope test, a waste of more than 330 hours of precious production time, according to the annual production capacity of 1 million tons, 200 tons of coal per hour, 330 hours less than 66,000 tons of coal. If the coal price is 500 yuan/ton, the economic benefit loss will reach 33 million yuan per year. With the coal Group, there are 52 pairs of operating mines, only the production time wasted in wire rope detection, the loss of economic benefits is huge every year.

(4)Unreliable. Manual inspection can only partially detect the more obvious damage outside the wire rope, and the wear, rust, broken wire, especially fatigue and other damage inside the wire rope can not be detected at all, so many major accident hidden dangers can not be found.

(5)Harmful. Once a wire rope breaks, it will inevitably cause significant harm. The equipment and mine repair, shutdown and rectification caused by wire rope accidents result in huge indirect losses; If an accident causes casualties, the harm to the families of the victims will be immeasurable and irreparable economically.

In order to change the passive management status of steel wire rope usage, Datong Coal Mine Group, like other coal mining enterprises, urgently needs to change the outdated management status of steel wire rope usage. It has been actively seeking reliable non-destructive testing equipment for steel wire ropes, hoping to use advanced and reliable testing techniques to improve the safety management level of coal transportation equipment.

2 TCK W portable non-destructive testing instrument improves the management of steel wire ropes

Improving the safety of steel wire rope operation has always been a difficult point in the safety management of mining elevators. The working conditions of mine hoisting are harsh and complex, and the steel wire rope is prone to corrosive damage due to long-term erosion by groundwater, acid-base corrosive substances or gases; During the lifting operation, the steel wire rope is constantly subjected to various stress concentrations such as compression, tension, bending, tension and compression, resulting in fatigue; During production operations, wire ropes are accidentally damaged or injured due to improper human operation. Other processes such as wire rope manufacturing, transportation, and storage can also cause damage to it. These damages can potentially cause wire rope accidents at any time.

Analysis and Exploration of Coal Mine Safety (2011-01) .149.

To solve the above-mentioned safety management difficulties, eliminate accident hazards, and effectively prevent accidents, it is undoubtedly necessary to apply advanced detection methods. Tongmei Group has a total of 52 pairs of main and auxiliary mines, with a high production load, and the safety of transportation improvement is particularly important. To ensure the safe operation of the steel wire rope, Tongmei introduced the TCK portable non-destructive testing instrument in 2006. Although it has indeed greatly improved the detection efficiency and safety management level of Tongmei's steel wire rope, it has taken a big step forward in improving equipment safety management. However, in the practical use of the equipment, we also feel that portable flaw detectors have not completely eliminated the impact of human factors on the intrinsic safety of the equipment. Moreover, the working conditions of the mine are complex, and for safety reasons, some lifting steel wire ropes cannot be detected by inspectors holding instruments. So, in order to completely solve the safety supervision problem of mine hoisting steel wire ropes, it is necessary to further innovate the management mode, and the best solution is to achieve online real-time continuous detection of steel wire ropes.

To explore advanced management modes for online automatic detection of steel wire ropes, Tongmei has made certain efforts. However, due to the lack of breakthroughs in traditional strong magnetic detection technology and the inability to overcome the drawbacks of poor passability, online real-time detection cannot be implemented. Therefore, for a long time, online real-time detection can only be a wish. Until the emergence of weak magnetic detection technology, online real-time detection of steel wire ropes truly became a reality. This is because the weak magnetic detection uses sensors with high sensitivity, tens of thousands of times higher than Hall elements. Therefore, even if the distance between the detection body and the measured object reaches 30mm, the signal can still be accurately picked up, achieving wide range non-contact detection. This significant breakthrough in technology has also determined that currently only weak magnetic detection technology can achieve true online real-time automatic detection of steel wire ropes. TCK Company, which possesses weak magnetic detection technology, has successfully developed an online real-time automatic detection system for TCK steel wire ropes after more than a year of development. This system adopts innovative weak magnetic detection core technology, and according to the safe operation needs of major transportation and upgrading equipment, it is equipped with customized mode combination detection devices, intelligent data acquisition conversion devices, photoelectric odometry devices, sound and light warning devices, terminal control devices, and online real-time automatic qualitative, quantitative, and positioning detection of internal and external damages such as wire breakage, wear, rust, fatigue, etc. of steel wire ropes. At the same time, it automatically analyzes various types of damage information, stores and records detection results, prints detection reports, and effectively eliminates various drawbacks of manual detection.

In 2009, Tongmei was equipped with a TCK real-time online automatic detection system for steel wire ropes in 21 main mines, which was used for online detection of single rope winding, four rope landing friction, and six rope landing friction hoist steel wire ropes. With the installation and use of the TCK steel wire rope online real-time automatic detection system, a new steel wire rope safety supervision mode has been created in Tongmei. By adopting the TCK steel wire rope online real-time automatic detection system, the operation of the lifting steel wire ropes in these mines has always been in a safe and controlled detection state, fundamentally eliminating accident hazards and ensuring safety; Due to the fact that testing can be completed simultaneously with normal production, the integration of production and testing not only increases effective operation time and improves production capacity, but also significantly reduces the idle energy consumption specifically used for steel wire rope testing. At the same time, using this system can scientifically extend the service life of steel wire ropes, save rope replacement time, and reduce rope costs. In summary, the use of this advanced online real-time automatic detection system for steel wire ropes has completely changed the backward situation of safety management for steel wire ropes in Tongmei elevators, solved the three major contradictions of "hidden dangers, waste, and low efficiency" for Tongmei, and achieved the triple management goals of "safety, conservation, and efficiency".

The application of TCK steel wire rope online real-time automatic detection system has innovatively improved the safety supervision mode of steel wire rope, making the transportation and lifting equipment management of Tongmei Group digital, intelligent, and automated, and successfully achieving a smooth integration with modern management in all aspects of Tongmei Group.

Author Introduction

Wang Tianzhong, male, born in September 1973, is a member of the CPC. He graduated from Taiyuan University of Technology with a bachelor's degree in electrical automation. He is an assistant engineer. Currently, he is the head of the mechanical section of the mechanical and electrical department of Datong Coal Mine Group. He has published more than ten papers, mainly engaged in the technical research and field management of mine mechanical and electrical equipment.