Abstract：The traditional detection method of wire rope is compared with the on-line automatic monitoring system. The principle, composition and application examples of wire rope on-line automatic monitoring system are emphatically introduced. From the practical application effect of Hulonggou Coal mine of Digjinwan Coal Industry Company of Datong Coal Mine Group, the automatic monitoring system solves the difficult problem of on-line automatic monitoring and real-time management of winch wire rope.

　　keyword： wire rope, detection, system, safety, benefit

　　Chinese library classification number：TD53

　　Document identification code：A

　　Article number：1672-3791(2009)08(c)-0010-01

　　As a "highly dangerous construction" in important lifting, lifting and transportation equipment, wire rope has always been regarded as the "lifeline" in these fields. For a long time, due to the lack of scientific and reliable testing equipment, the use of wire rope safety has been a "blind spot" or "danger source" in the management of major equipment. In order to ensure the safety of the rope, the rope unit generally adopts the method of manual detection or regular rope change. The cross-sectional area of steel wire decreases due to steel wire wear and rust. The internal properties of the steel wire change due to fatigue, surface hardening and corrosion; Improper use of rope deformation and so on. In service, the wire rope may be damaged by single line breakage, corrosion, wear, random line, etc. All kinds of damage will cause the fault of the wire rope. Due to the importance of the use of wire rope and the structural performance characteristics of wire rope, when there is a serious defect in the wire rope, the whole wire rope will be scrapped, therefore, once the wire rope fails, it will be irreparable.

　　Technically, it is generally recognized that the critical point of strength loss to determine whether the wire rope is safe is 15%. An authoritative department in the United States has made statistics on 8000 steel wire rope experiment stations and application sites around the world, and the result is that 10% of the steel wire rope in use has a strength loss of more than 15%, which is in a dangerous state; There are 2% in use of steel wire rope strength loss of more than 30%, in an extremely dangerous state. About 70% of wire ropes that are forcibly replaced have little or no reduction in strength. Cause great waste. The rope that should be changed was not changed, and the rope that should not be changed was forced to be changed. All this is due to the imperfect and unscientific means of wire rope monitoring and management.

　　At present, most of the coal mines in China still use manual inspection on the rope of hoisting winch. There are two disadvantages to this approach：

　　1、Boot energy consumption is large, manual detection of steel wire rope with visual, hand touch steel wire rope running speed within 0.3-0.5m/s, if there are doubts in the place also have to stop with calipers for inspection. For a certain section of heavy mud wire rope need to be cleaned before detection, and need to be tested once a day. Take Longhugou Mine of Digjinwan Coal Mine Company of Datong Coal Mine Group as an example: the rope length of the auxiliary inclined shaft hoist is 770m, and the motor power is 1000kw. Each time the steel wire rope is tested for about 1h, the steel wire rope testing alone causes a waste of 300-400h startup energy consumption in a year. Power consumption 400000 kwh.

　　2、The data is not reliable, and the wire rope should be lubricated at least 2 times a month when in use. Before lubrication, use a wire brush to remove the dirt on the wire rope and clean it with kerosene, but then dip the lubricating oil heated to more than 800C into the wire rope to soak the lubricating oil into the rope core. Manual inspection can only partially detect the external damage of the wire rope, while the internal wire break, wear, rust, especially fatigue and other conditions of the wire rope can not be detected, so many major hidden dangers are difficult to find.

　　On-line monitoring of wire rope breakage and abrasion has been studied for 100 years. Because it is a unique material with a slender structure, ordinary electronic instruments are difficult and too late to analyze and process, that is, the use of the most advanced sensors to collect signals, and false detection and missing detection are inevitable.

　　In recent years, the expensive steel wire rope non-destructive testing equipment introduced from the United States, the United Kingdom, Japan, Canada and other countries has been abandoned, or limited to laboratory research. However, the use of wire rope in the real sense of online real-time monitoring is still a technical gap in the global scope.

　　The advent of wire rope on-line automatic monitoring system makes it a reality to replace manual detection with scientific instruments. Wire rope online automatic monitoring system eliminates the influence of human factors to the greatest extent. After the system is pre-adjusted by technicians, it enters the operating state of automatic calibration and automatic detection, and the detection results are stable and reliable.

　　The principle of wire rope online automatic monitoring system is: in the operation path of the wire rope to be inspected, a reasonable selection of monitoring points, as far as possible to complete the maximum travel of real-time monitoring, monitoring in the event of danger signals, the first time transmitted to the equipment operating system, sound and light alarm and can optionally set automatic or manual shutdown and other emergency treatment methods to ensure the safe operation of equipment.

　　Wire rope online automatic monitoring system is mainly composed of modal weak magnetic loading device, mode combination detection system, steady-state operation holding device, multifunctional data acquisition conversion workstation, sound and light warning system and terminal program master control station. Detection process: Firstly, the weak magnetic loading of the steel wire rope under test is completed by weak magnetic loading, so that it is in a stable state to be measured; Secondly, the whole state information of the wire rope under test is extracted and the original detection information is output by the high-performance sensor. The sensor should be installed in the position where the swing of the wire rope is minimal. The installation should have a certain degree of flexibility, and the suspension type is fixed to avoid shaking of the wire rope in the probe; Only the wire rope that passes through the sensor section can be detected, so when there is a dead zone in the detection, multi-point detection should be selected. Keep away from heat sources, magnetic sources, and other instruments affected by strong magnetic fields. After receiving the original detection information, the multi-functional data acquisition and conversion workstation completes the required data conversion, and realizes the preliminary processing and information storage of the original data; Through wired or wireless communication transmission, the operating specification damage signal is transmitted to the main control center in real time.

　　According to the People's Republic of China coal industry standard MT/T970-2005 "Wire rope (cable) online non-destructive quantitative testing method and judgment rules" provisions. The processing results of multifunctional data acquisition and conversion workstation provide early warning signals, and judge the safety state of the wire rope according to the different damage degree.

　　After the application of wire rope online automatic monitoring system in Hulonggou Mine of Digjinwan Coal Industry Company of Datong Coal Mine Group, various drawbacks of manual detection are completely eliminated and the occurrence of broken rope accidents is avoided. It plays a very important role in ensuring the safety of production.

　　At the same time, the automatic monitoring system has also brought considerable economic benefits to Hulonggou Mine. Only detected energy consumption saving of nearly 300,000 yuan. The wire rope will not be forcibly replaced in advance because of the automatic detection system, reducing the consumption by 1/3, saving the cost of 600,000 yuan. Reduce the downtime detection time 4/5, create a profit of 1 million yuan. Annual savings of more than 2 million yuan. At the same time, it provides a reliable guarantee for the safe use of rope.

　　Wire rope automatic online monitoring system plays a very important role in the use and maintenance of wire rope, which provides technical support and basis for scientific and systematic management and use of wire rope, ensuring work efficiency and eliminating safety hazards. Science reduces costs and creates considerable economic benefits.

　　About the author：zhu dagen(1972- )，Male, Datong Coal Mining Group digging Jinwan coal industry company assistant engineer.