= = +
(2)
.
S
N B
t
(3)
For the moving rope, metal cross section is a function of
the length what is the goal of this type of non-destructive
testing. Therefore equation (3) can be reduced to the
following form.
.
S l S
N B N B v
l t l
= =
(4)
Effective metal cross section of the main flux at some
point along the rope l is given in equation (5), where l
represents the longitudinal coordinate of the rope, d is
median length of magnetic flux in the ropes, and x current
coordinate of magnetized rope. The expected minimum
signal level, the electromotive force in V is given by
expression (6).
( ) ( )
1
.
l d
l
S l S x dx
d
+
=
(5)
4
2 10 . N
= (6)
It is important to note that the rope speed value in the
expression (4) is 1 m/s what is the usual standard speed of
the rope in non-destructive testing, rope saturation
induction is about 2T, and change of the metal cross
section is 0.10 mm2/mm. Detection of impairment loss of
metal on a rope is achieved with an integrated main flux
signal, while for other defects such as corrosion the
original and differentiated signal from the sensor (coil) are
of great importance.
IV. HARDWARE AND SOFTWARE OF THE ACQUISITION
DEVICE
The acquisition and primary signal processing in the
system is accomplished by the device consisting of circuits
for processing of analog and digital signals. The block
representation of the device is given in Fig 3.
Figure 3. Block representation of the acquisition device.
The main flux signal is fed into the analog subsystem
where it is processed. In order to fulfill the requirements
for sampling freqency and avoid overlapping in the
spectrum of digitized signal, the signal is passed through a
low pass filter first. It is a resistor-capacitor filter with cut-
off freqency of 1000 Hz. The output of the low pass filter
feeds a unity gain amplifier. The purpose of the amplifier
is to isolate input and output stages and provide for high
impedance input for the sensor signal which is intrinsically
of low amplitude and low power. Then, the signal is routed
to the inputs of integrator and differentiator and by the
146
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Journal, Vol. 4
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Radovanovi et al.: Signal Acquisition and Processing in the Magnetic Defectoscopy of Steel Wire Ropes 147
Nowadays, magnetic defectoscopy is a very useful
method for testing condition of steel wire ropes
worldwide. European Standard EN12927, American
Standard ASTM E 1571, as well as numerous professional
organizations and associations have included this method
as a valid standard. In Serbia, this method has been used
for more than 20 years, what caused that the magnetic
defectoscopy is included in the technical regulations as a
permissible method for testing of steel wire ropes [8].
NDT method that provides assessment of the steel wire
rope condition using magnetic defectoscopy is based on
accepted norms that regulate this matter. Magnetic
defectoscopy provides highly reliable data about rope
condition, therefore the segments where defects were
identified can easily be localized. By combining signals
from multiple sensors it is possible to describe the
observed changes in the geometry of steel rope both
qualitatively and quantitatively. In this way, it can be
determined whether the observed changes in the steel rope
are in the range of standard limits, near the limit values or
even exceed those values. Assessment of condition of steel
ropes, based on the results of NDT magnetic defectoscopy,
is conducted in accordance with applicable regulations and
standards.
Before testing, simulations of known defects are
performed in order to calibrate each sensor. Fig. 5a) shows
the damage to the steel wire rope created by mechanical
shock on the rope. A typical display of the results that
show this defect as a function of its position is given in
Fig. 5 b).
a)
b)
Figure 5. a) Mechanical shock on steel wire rope b)
display signals during testing of this defect.
Top signal with 25mV/div resolution is obtained from
the outer inductive sensor, while signal in the middle is
from the internal inductive sensor (resolution 10mV/div)
where the defect is clearly visible. The bottom signal
(resolution 100mV/div) is an integrated signal from
acquisition devices. Two top signals show that defect is
present and the defects position.
Integrated signal in the place of defect shows detected
irregularity and its intensity is proportional to the loss of
metal in cross section which is very low in this example.
Another type of defect that is common is broken wires in
the steel wire rope (Fig. 6 a).
a)
b)
Figure 6. a) Broken wire defect in steel wire rope b)
display signals during testing of steel wire rope with this
defect
The system of sensors detects damage and displays it as
shown in Fig. 6 b). Thanks to a system of various types of
sensors it is possible to clearly detect start of the defect,
type of defect and its position thanks to a signal from the
rotary encoder. The number of broken wires inside the
rope is possible to determine from the amplitude of the
bottom signal. The loss of metal in cross-section due to
broken wires should be calculated by taking into account
its number and cross section at the reference length.
Due to the complex wire rope defects, damage to a
greater number of wires that steel rope is made of, each
interrupt or interfere individually can be noticed. One such
example is given in Fig. 7.
148 Telfor Journal, Vol. 4, No. 2, 2012.
Figure 7. Display of complex defect signals on steel wire
rope, a few consecutive defects together
The results arising from the application of these
methods are highly important and relate to the following:
eliminate the human factor as less reliable in the process of
regular monitoring of steel ropes; Increased safety of staff
and equipment in the work process; Provide identification
of hidden defects and damage; Provide a record of steel
rope condition taken after NDT; Better assessment of steel
rope condition taken in the process of making a decision
about further use, the possibility to extend the use of the
steel wire rope in accordance with the results of NDT.
In addition to NDT magnetic defectoscopy and its
analysis of record, overall assessment of the steel wire
rope condition depends on conditions of operation, quality
and scope of maintenance, compliance with regulations
governing the required type of installation and the quality
management system applied by the user.
VII. CONCLUSION
The presented system provides an effective inspection
of wire ropes and determination of the current condition of
ropes. Measurement procedure is used to identify damage
to ropes and provides for information on the type and
extent of defects, while complying with the technical
regulations and standards governing the non-destructive
testing of steel wire ropes. Testing has shown that the
system is reliable, compact, easy to use and suitable for
field work in difficult conditions, what is often the case in
practice.
ACKNOWLEDGEMENTS
We are particularly indebted to Mr. Stevan Nikolic, the
head of the ICEF laboratory, prof. dr Dejan Zivkovic, the
former director of Innovation Center, Mr. Vladimir
Bogdanovic, the mechanical constructor of the magnetic
sensor and Innovation Center of the School of Electrical
Engineering in Belgrade as the creators of this system.
REFERENCES
[1] Tomaiuolo, F.G. and J.G. Lang. Method and Apparatus for
Nondestructive Testing of Magnetically Permeable Bodies Using a
First Flux to Saturate the Body and a Second Flux Opposing the
First Flux to Produce a Measurable Flux. US Patent 4,495,465
(January 1985).
[2] Whitehead, E.A.N. Method of Obtaining an Electrical Signal
Proportional to the Cross-Sectional Area of a Magnetic Tube or
Rod, UK Patent 913,780 (December 1962).
[3] Weischedel, H.R. The Inspection of Wire Ropes in Service, A
Critical Review. Materials Evaluation. Vol. 43, No.13. American
Society for Nondestructive Testing, pp. 1592-1605.
[4] Wall, T.F.; Hainsworth, C.H.; , "The penetration of alternating
magnetic flux in wire ropes," Electrical Engineers, Journal of the
Institution of , vol.71, no.428, pp.374-379, August 1932.
[5] Moriya, T.; Sugawara, M.; Tsukada, K.; , "Magnetic nondestructive
evaluation of corrosion in wire ropes," OCEANS '04. MTTS/IEEE
TECHNO-OCEAN '04 , vol.4, no., pp.1904-1909 Vol.4, 9-12 Nov.
2004.
[6] Feng Guihong; Yang Xiang; Zeng Yifan; Zhang Bingyi; ,
"Research of examining steel wire with no damaging method,"
Electrical Machines and Systems, 2005. ICEMS 2005. Proceedings
of the Eighth International Conference on , vol.3, no., pp.2245-
2249 Vol. 3, 29-29 Sept. 2005.
[7] ATmega16, Users Guide, Atmel Corporation, 2010,
Available: www.atmel.com
[8] SRPS EN 12927, Serbian Standard, Zavod za standardizaciju, 2011.