CN109975115B - Device and method for detecting multi-wire spiral contact inside steel wire rope - Google Patents
Device and method for detecting multi-wire spiral contact inside steel wire rope Download PDFInfo
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Abstract
The invention discloses a device and a method for detecting contact fatigue, abrasion and damage of a multi-wire spiral inside a steel wire rope, wherein the device comprises a supporting device, wherein the supporting device is provided with a fatigue steel wire loading assembly and a loading steel wire assembly which is in spiral contact with the fatigue steel wire at a certain crossing angle and prestress; a condition monitoring device; the device can simulate the contact fretting fatigue damage condition of the multi-steel-wire spiral inside the steel wire rope, monitor the torque, the friction force, the temperature field and the friction coefficient of the multi-steel-wire spiral inside the steel wire rope in real time, reveal the contact fretting fatigue fracture mechanism of the multi-steel-wire spiral, and evaluate the fretting damage evolution and the fretting fatigue life of the multi-steel-wire.
Description
Technical Field
The invention relates to a device and a method for detecting contact fatigue, abrasion and damage of a multi-wire spiral inside a steel wire rope, in particular to a test device and a method for simulating composite micro-motion modes of pull-down, pull-torsion and the like of the multi-wire spiral contact inside the steel wire rope and monitoring the contact micro-motion fatigue and frictional wear conditions of the multi-wire spiral inside the steel wire rope.
Background
The steel wire rope is a three-dimensional spiral space structure formed by twisting wires into strands at a certain twisting angle and twisting the strands into ropes, has the advantages of high bearing capacity, good flexibility, stable motion, no noise and the like, and is widely applied to the fields of mine hoists, cranes, elevators, aerial cableways and the like.
The steel wire rope is a complex member consisting of a plurality of spiral elements (steel wires or strands), and in the mine hoisting process, the hoisting steel wire rope bears cyclic tensile and bending loads, so that micron-sized relative slippage and torsion are generated among the steel wires in the rope, and tangential force action is generated among the steel wires under the action of contact load, namely fretting wear is generated. The mine hoisting steel wire rope is subjected to cyclic stretching and torsional coupling action to cause crack initiation, expansion and final fracture, so that the fatigue and wire breakage of the steel wire rope are accelerated, and the use reliability of the steel wire rope is influenced. Therefore, it is necessary to develop a device for detecting the contact fatigue, wear and damage of the multi-filament spiral inside the steel wire rope.
The invention provides a device and a method for detecting contact fatigue, abrasion and damage of a multi-wire spiral in a steel wire rope, which dynamically monitor torque, friction force, temperature field and friction coefficient among steel wires under different fretting fatigue parameters (fretting frequency, fretting amplitude, alternating load, torsion angle, contact force, crossing angle and contact radian) in the fretting fatigue process of the multi-wire spiral under a spiral structure in real time, and are used for revealing a multi-wire spiral contact fretting fatigue fracture mechanism and evaluating the fretting damage evolution and the fretting fatigue life of the multi-wire.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and provides a device and a method for detecting contact fatigue, abrasion and damage of a multi-wire spiral inside a steel wire rope, which can simulate composite micromotion modes such as pull-pull, pull-twist and the like of the multi-wire spiral contact mode inside the steel wire rope under different working conditions on one tester.
In order to achieve the technical purpose, the invention adopts the following technical scheme:
a multi-wire spiral contact fatigue, abrasion and damage detection device in a steel wire rope comprises a supporting device, wherein a fatigue steel wire is vertically arranged on the supporting device, and a fatigue steel wire rotating mechanism is arranged at one end of the fatigue steel wire and used for driving the fatigue steel wire to rotate around the axis of the fatigue steel wire; the other end is equipped with tired steel wire straining device for carry out the pretension force loading to tired steel wire, still include:
a load wire assembly for making helical contact with the fatigue wire at an intersection angle and with a pre-stress, the load wire assembly comprising: a concave wire loading mechanism and a convex wire loading mechanism, wherein,
concave steel wire loading mechanism sets up in one side of tired steel wire, includes:
the front end of the first door-shaped support frame is provided with a concave loading block, and the concave loading block is provided with a horizontal groove for embedding a concave loading steel wire;
the two groups of first loading units are arranged on the left side and the right side of the first portal-shaped support frame in a reverse symmetry mode, each group of first loading units comprises a first torsion driving unit for driving the concave loading steel wire to rotate around the axis of the first loading unit and a first tension loading unit for applying tension to the concave loading steel wire, the middle part of the concave loading steel wire is embedded in a groove of the concave loading block, one end of the concave loading steel wire is connected with the first torsion driving unit, and the other end of the concave loading steel wire is connected with the first tension loading unit;
the first crossing angle adjusting mechanism is used for adjusting the crossing angle between the concave loading steel wire and the fatigue steel wire;
the first positioning mechanism is used for driving the concave loading steel wire to contact with the fatigue steel wire with certain prestress;
convex steel wire loading mechanism sets up in the opposite side of tired steel wire, includes:
the front end of the second door-shaped support frame is provided with a convex loading block, and the convex loading block is provided with a horizontal groove for embedding a convex loading steel wire;
the two groups of second loading units are arranged on the left side and the right side of the second portal supporting frame in a reverse symmetry mode, each group of second loading units comprises a second torsion driving unit used for driving the loading steel wire to rotate around the axis of the second torsion driving unit and a second tension loading unit used for applying tension to the loading steel wire, the middle part of the convex loading steel wire is embedded in the groove of the convex loading block, one end of the convex loading steel wire is connected with the second torsion driving unit, and the other end of the convex loading steel wire is connected with the second tension loading unit;
the second crossing angle adjusting mechanism is used for adjusting the crossing angle between the convex loading steel wire and the fatigue steel wire;
the second positioning mechanism is used for driving the convex loading steel wire to contact with the fatigue steel wire with certain prestress;
a condition monitoring device comprising:
the first force sensor is connected with the fatigue steel wire loading assembly and used for monitoring the alternating load of the fatigue steel wire in real time;
the angle sensor is connected with the fatigue steel wire loading assembly and is used for monitoring the rotation angle of the fatigue steel wire in real time;
the static torque sensor is connected with the fatigue steel wire loading assembly and is used for monitoring the torque change of the fatigue steel wire in real time;
the second force sensor is arranged between the tension loading unit and the portal support frame and used for monitoring the prestress change of the loading steel wire;
and the third force sensor comprises two force sensors, wherein one force sensor is arranged at the bottom of the concave loading block and used for monitoring the change of the friction force between the concave loading steel wire and the fatigue steel wire, and the other force sensor is arranged at the bottom of the convex loading block and used for monitoring the change of the friction force between the convex loading steel wire and the fatigue steel wire.
The first intersection angle adjusting mechanism comprises a first loading rod and a first rotating table, wherein one end of the first loading rod is fixedly connected with the rear end of the first portal-shaped supporting frame, the other end of the first loading rod is connected with the first rotating table, and a first rotating table base is fixedly connected with the first positioning mechanism;
the second intersection angle adjusting mechanism comprises a second loading rod, a fixed block and a second rotating table, wherein one end of the second loading rod is fixedly connected with the rear end of the second door-shaped supporting frame, the other end of the second loading rod is connected with the fixed block, and the fixed block is fixedly connected with the second rotating table;
the first positioning mechanism and the second positioning mechanism have the same structure and both comprise: the bottom plate, fixed connection encloses into four rectangular optical axis supporting seats on the bottom plate, is equipped with the optical axis of a vertical setting on every optical axis supporting seat, and every slides on the optical axis and is equipped with the slider, set up between four sliders and with four slider fixed connection's backup pad, be equipped with the promotion in the backup pad spill loading piece and convex loading piece and fatigue steel wire in close contact with's thrustor, thrustor includes: the loading plate is arranged on the linear guide rail in a sliding mode through a guide rail sliding block, a circular through hole is formed in the middle of the bottom plate, and a strip-shaped hole is formed in the position, located right above the circular through hole, of the rear end of the supporting plate;
one end of the nylon rope is connected with the balancing weight, the other end of the nylon rope penetrates through the circular through hole and the strip-shaped hole in sequence and then is connected with one end of the loading plate, which is far away from the fatigue steel wire, and the loading plate horizontally moves towards the fatigue steel wire on the linear guide rail under the action of the gravity of the balancing weight, wherein,
a driving mechanism in the first positioning mechanism is connected with the first door-shaped support frame through a first loading rod;
a driving mechanism in the second positioning mechanism is connected with one end of a door-shaped loading rod, the other end of the door-shaped loading rod is rotatably connected with a convex loading block through a rotating shaft, a third force sensor is fixedly connected to the bottom of the convex loading block, and the bottom of the third force sensor is slidably connected with a sliding groove in a second small bearing frame through a sliding plate.
The sliding block is provided with a locking screw, so that the sliding block can be fixed at any height position of the optical axis.
The fatigue steel wire rotating mechanism is a stepping motor, the fatigue steel wire pre-tensioning mechanism is an electric cylinder, and a driving shaft of the stepping motor and a driving shaft of the electric cylinder are fixedly connected with the fatigue steel wire through a clamp respectively.
The torsion driving unit is a steering engine, an output rotating shaft of the steering engine is connected with a steel wire rope chuck through a connecting rod, and one end of a loading steel wire is connected to the steel wire rope chuck;
the tension loading unit is a worm gear mechanism, wherein a worm is connected with a handle and used for rotary loading; the turbine winds one end of the loading steel wire, and the loading steel wire can be wound and self-locked.
The first force sensor and the second force sensor are tension sensors; the third force sensor is a pull and pressure sensor.
The supporting device comprises four bottom beams which are encircled to be rectangular, four supporting stand columns which are symmetrically arranged on the bottom beams, four reinforcing ribs are arranged at the bottom ends of the supporting stand columns, four upper bearing beams which are encircled to be rectangular are arranged at the tops of the supporting stand columns, and four bearing seat bearing beams and four middle bearing beams which are encircled to be rectangular are arranged in the middle of the supporting stand columns.
The invention further discloses a detection method using the device for detecting the contact fatigue, the abrasion and the damage of the multi-filament spiral in the steel wire rope, which comprises the following steps:
a. connecting a fatigue steel wire on the fatigue steel wire loading assembly, and measuring the pretension force of the fatigue steel wire in real time through a first force sensor;
b. the concave steel wire loading mechanism is connected with a concave loading steel wire, and the concave loading steel wire on the concave loading block keeps a preset cross angle to be in close contact with the fatigue steel wire by adjusting the first cross angle adjusting mechanism and the first positioning mechanism;
the convex loading steel wire loading mechanism is connected with a convex loading steel wire, and the convex loading steel wire on the convex loading block keeps a preset cross angle and is in close contact with the fatigue steel wire by adjusting the second cross angle adjusting mechanism and the second positioning mechanism;
the pretensioning force of the concave loading steel wire and the pretensioning force of the convex loading steel wire are measured in real time through the second force sensor;
c. the fatigue steel wire is enabled to generate torsional motion by controlling the fatigue steel wire torsion unit, and the torsion driving units on the concave steel wire loading mechanism and the convex steel wire loading mechanism are respectively opened, so that the concave loading steel wire and the convex loading steel wire also generate torsional motion, and the multi-axis fretting fatigue phenomenon of the fatigue steel wire is realized;
applying alternating load to the fatigue steel wires by controlling the fatigue steel wire pre-tensioning mechanism to enable the fatigue steel wires to be changed in a stretching and contracting mode within a set alternating stress range, and enabling the fatigue steel wires and the loading steel wires to generate micron-sized relative dislocation, wherein the relative dislocation displacement between the steel wires is obtained by reducing the proportion of a measurement value built in the fatigue steel wire pre-tensioning mechanism;
measuring the alternating load of the fatigue steel wire in real time through a first force sensor;
measuring the torsion angle of the fatigue steel wire in real time through an angle sensor;
measuring the torque of the fatigue steel wire in real time through a static torque sensor;
monitoring the prestress change of the loading steel wire in real time through a second force sensor;
the friction force change between the loading steel wire and the fatigue steel wire is monitored in real time through a third force sensor
Monitoring the temperature change of the frictional wear of the contact surface of the steel wire in real time by using a thermal infrared imager;
recording alternating load, torque, torsion angle, friction force and temperature field of the fatigue steel wire in real time, and stopping the test until the fatigue steel wire is broken due to spiral contact fretting fatigue damage;
d. changing the frequency and the positive and negative rotation angle amplitude of the torsion driving unit, changing the vibration frequency and the amplitude of the torsion driving unit, adjusting a crossing angle adjusting mechanism and a positioning mechanism, and performing a multi-steel-wire spiral contact fretting fatigue test under the conditions of different fretting frequencies, torsion angles, fretting amplitudes, crossing angles and contact loads;
under the stretching and twisting compound motion mode, one motion is fixed, and the multi-steel-wire spiral contact fretting fatigue test under the compound or single motion mode of two motion modes can be realized.
The concave loading steel wires comprise two concave loading steel wires, namely a first concave loading steel wire and a second concave loading steel wire, wherein,
the middle part of the first concave loading steel wire is embedded on the concave loading block, one end of the first concave loading steel wire is connected with the first torsion driving unit at one side of the first door-shaped supporting frame, and the other end of the first concave loading steel wire is connected with the first tension loading unit at the other side of the first door-shaped supporting frame;
the middle part of a second concave loading steel wire is embedded on the concave loading block, one end of the second concave loading steel wire is connected with the first tension loading unit on one side of the first portal-shaped support frame, and the other end of the second concave loading steel wire is connected with the first torsion driving unit on the other side of the first portal-shaped support frame;
the two convex loading steel wires are respectively a first convex loading steel wire and a second convex loading steel wire, wherein the middle part of the first convex loading steel wire is embedded on the convex loading block, one end of the first convex loading steel wire is connected with a second torsion driving unit at one side of the second portal-shaped support frame, and the other end of the first convex loading steel wire is connected with a second tension loading unit at the other side of the second portal-shaped support frame;
the middle part of the second convex loading steel wire is embedded on the convex loading block, one end of the second convex loading steel wire is connected with the second tension loading unit on one side of the second portal support frame, and the other end of the second convex loading steel wire is connected with the second torsion driving unit on the other side of the second portal support frame.
The rear side of the concave loading block is provided with symmetrical threaded holes, two through holes are symmetrically formed in the portal support frame corresponding to the threaded holes, a threaded rod with a nut penetrates through the through holes in the portal support frame, the horizontal position of the concave loading block is adjusted by rotating the position of the nut on the threaded rod, and different radians of contact between the loading steel wire and the fatigue steel wire are achieved.
The invention has the beneficial effects that: due to the adoption of the technical scheme, the invention can realize the composite fretting friction and wear tests of pulling-pulling, pulling-twisting and the like under the simulation of the multi-steel-wire spiral contact mode in the steel wire rope, so as to reveal the multi-steel-wire spiral contact friction and wear mechanism in the steel wire rope and evaluate the wear damage evolution and the fatigue life of the steel wire in the steel wire rope.
The fatigue damage state of the multi-steel-wire spiral contact micromotion in the steel wire rope can be simulated, the electric cylinder, the turbine worm tension loading unit, the steering engine and the stepping motor are adopted, stable and accurate micromotion, prestress and torsion angles can be continuously applied, the torque, the friction force, the temperature field and the friction coefficient of the multi-steel-wire spiral contact micromotion in the steel wire rope can be monitored in real time, the fatigue fracture mechanism of the multi-steel-wire spiral contact micromotion is revealed, and the micromotion damage evolution and the micromotion fatigue life of the multi-steel-wire are evaluated.
The test device is simple and convenient to operate, good in effect and wide in practicability in the technical field.
Drawings
FIG. 1 is a front view of the apparatus of the present invention;
wherein: 1. an angle sensor; 2. a stepping motor; 3. an upper load beam; 4. a static torque sensor; 5. a bearing seat; 6. fatigue steel wires; 7. a bearing block carrier bar; 8. supporting the upright post; (9, 23) a base plate; 10. a middle load beam; (11, 11B), a counterweight; 12. an electric cylinder; 13. an electric cylinder bottom plate; 14. a bottom beam; 15. a support block; 16. a coupling; 17. a stepper motor base plate; 18. an upper connecting piece; 19. a lower connecting piece; 20. a bearing block base plate; 21. an upper clamp; 22. a thermal infrared imager; 24. a lower clamp; 25. a tension sensor; 26. reinforcing ribs;
FIG. 2 is a schematic view of the support block of the present invention;
wherein, 15A, the pillar; 15B, flat plate;
FIG. 3 is a schematic view of the contact between a loading wire and a fatigue wire according to the present invention;
40, a concave loading block; 52 a male loading block; 64. a loading wire on the convex loading block; 65. a loading wire on the concave loading block;
FIG. 4 is a schematic view of a first load wire assembly according to the present invention;
wherein, (27, 27B), steering engine; (28, 28B), a worm gear mechanism; (29, 29B), micro pull, pressure sensors; 30. a first portal support frame; 31. a first loading lever; 32. A first rotating table; 33. an optical axis; 34. a support plate; 35. a loading plate; 36. a connecting rod; 37. a steel wire rope chuck; 38. A rudder mount; 39. a first small carrier; 40. a concave loading block; 41. a threaded rod; 42. a slide rail slider; 43. an optical axis supporting seat; 44. a slider;
FIG. 5 is a schematic view of a connection structure between a concave loading block and a door-shaped supporting frame in the first loading steel wire assembly according to the present invention;
59, a nut;
FIG. 6 is a schematic structural diagram of a concave loading block according to the present invention
61, a threaded hole;
FIG. 7 is a schematic view of the structure of the support plate of the present invention;
wherein, 34A, a strip-shaped hole;
FIG. 8 is a schematic structural diagram of a base plate according to the present invention;
23A, a circular hole;
FIG. 9 is a schematic structural view of a load plate according to the present invention;
35A, a strip-shaped through groove is formed in the loading plate;
FIG. 10 is a schematic view of a second load wire assembly according to the present invention;
wherein, (27C, 27D), steering engine; (28C, 28D), a worm gear mechanism; (29C, 29D), micro-pull, pressure sensors; 37C, a steel wire rope chuck; (38C, 38D), steering engine mount; the second door-shaped support frame; 47. a fixed block; 50. a second small bearing frame; 51. a rotating shaft; 52. a convex loading block; 53. a second loading lever; 54. a second rotating table;
FIG. 11 is a schematic view of the structure of two loading units in the second loading wire assembly of the present invention;
46. a door-shaped loading lever; (55, 55B), a fixed pulley; 56. a tension sensor; 57. a slide plate;
FIG. 12 is a schematic view of a second small loading frame according to the present invention;
50A, a clamping groove;
FIG. 13 is a schematic view of the construction of the present invention;
66. a square block with a through hole; 67. a semi-cylinder with a threaded hole; 68. a socket head cap screw;
FIG. 14 is a schematic view of a connection structure of an optical axis and a slider according to the present invention;
62. locking the screw;
FIG. 15 is a schematic view of the rudder mount of the present invention;
63. a micro-bearing;
FIG. 16 is a schematic view of the tension loading unit of the present invention;
fig. 17 is a diagram showing the positional relationship of two load wire mechanisms of the present invention.
Detailed Description
An embodiment of the invention is further described below with reference to the accompanying drawings:
as shown in fig. 1-14, the device for detecting contact fatigue, wear and damage of multi-thread spiral inside a steel wire rope mainly comprises a supporting device, a fatigue steel wire loading assembly arranged on the supporting device, a crossing angle adjusting mechanism and a positioning mechanism arranged on the supporting device, wherein the crossing angle adjusting mechanism is used for adjusting the crossing angle between a loading steel wire and the fatigue steel wire;
the positioning mechanism is used for driving the loading steel wire to contact with the fatigue steel wire with a certain prestress;
the supporting device comprises four bottom beams 14 which are encircled to be rectangular, four supporting upright posts 8 which are symmetrically arranged on the bottom beams 14, four reinforcing ribs 26 which are used for ensuring stability are arranged at the bottom ends of the supporting upright posts 8, four upper bearing beams 3 which are encircled to be rectangular are arranged at the top parts of the supporting upright posts 8, four bearing seat bearing beams 7 and four middle bearing beams 10 which are encircled to be rectangular are arranged in the middle parts of the supporting upright posts 8, an electric cylinder bottom plate 13 which is connected with the bottom beams 14 through bolts, a stepping motor bottom plate 17 which is fixed on the upper supporting beams 3 through bolts, a bearing seat bottom plate 20 which is fixed on the bearing seat supporting beams 7 through bolts, supporting blocks 15 which are connected with the stepping motor bottom plate 17 through bolts, and the supporting blocks 15 are provided with four supporting columns;
the fatigue steel wire loading assembly comprises a vertical rotation driving mechanism and a vertical loading assembly;
the vertical rotation driving mechanism comprises a bearing seat 5 arranged on a bearing seat bottom plate 20, a lower connecting piece 19 penetrating through the bearing seat 5, an upper clamp 21 connected with the lower connecting piece 19 through threads, a stepping motor 2 fixed on a stepping motor bottom plate 17 through bolts, and an upper connecting piece 18 connected with the stepping motor 2 through a coupler, wherein the upper connecting piece is connected with the lower connecting piece through a static torque sensor 4;
the vertical loading assembly comprises an electric cylinder 12 fixed on an electric cylinder bottom plate 13 through a bolt, and a lower clamp 24 connected with the electric cylinder through a tension sensor 25, wherein a fatigue steel wire 6 is vertically fixed between an upper clamp 21 and a lower clamp 23, and the fatigue steel wire 6 is fixed by the clamp and clamped by a clamping plate screwed by a screw;
as shown in fig. 3 to 14, the load wire assembly includes: a concave steel wire loading mechanism and a convex steel wire loading mechanism which are symmetrically arranged at the left side and the right side of the fatigue steel wire,
concave steel wire loading mechanism sets up in one side of tired steel wire, includes:
the front end of the first door-shaped support frame is provided with a concave loading block, and the concave loading block is provided with a horizontal groove for embedding a concave loading steel wire;
the two groups of first loading units are arranged on the left side and the right side of the first portal-shaped support frame in a reverse symmetry mode, each group of first loading units comprises a first torsion driving unit for driving the concave loading steel wire to rotate around the axis of the first loading unit and a first tension loading unit for applying tension to the concave loading steel wire, the middle part of the concave loading steel wire is embedded in a groove of the concave loading block, one end of the concave loading steel wire is connected with the first torsion driving unit, and the other end of the concave loading steel wire is connected with the first tension loading unit; the first crossing angle adjusting mechanism is used for adjusting the crossing angle between the concave loading steel wire and the fatigue steel wire; the first positioning mechanism is used for driving the concave loading steel wire to contact with the fatigue steel wire with certain prestress;
convex steel wire loading mechanism sets up in the opposite side of tired steel wire, includes:
the front end of the second door-shaped support frame is provided with a convex loading block, and the convex loading block is provided with a horizontal groove for embedding a convex loading steel wire;
the two groups of second loading units are arranged on the left side and the right side of the second portal supporting frame in a reverse symmetry mode, each group of second loading units comprises a second torsion driving unit used for driving the loading steel wire to rotate around the axis of the second torsion driving unit and a second tension loading unit used for applying tension to the loading steel wire, the middle part of the convex loading steel wire is embedded in the groove of the convex loading block, one end of the convex loading steel wire is connected with the second torsion driving unit, and the other end of the convex loading steel wire is connected with the second tension loading unit; the second crossing angle adjusting mechanism is used for adjusting the crossing angle between the convex loading steel wire and the fatigue steel wire; the second positioning mechanism is used for driving the convex loading steel wire to contact with the fatigue steel wire with certain prestress;
the first intersection angle adjusting mechanism comprises a first loading rod and a first rotating table, wherein one end of the first loading rod is fixedly connected with the rear end of the first portal-shaped supporting frame, the other end of the first loading rod is connected with the first rotating table, and a first rotating table base is fixedly connected with the first positioning mechanism;
the second crossed angle adjusting mechanism comprises a second loading rod, a fixed block and a second rotating table, wherein one end of the second loading rod is fixedly connected with the rear end of the second door-shaped supporting frame, the other end of the second loading rod is connected with the fixed block, and the fixed block is fixedly connected with the second rotating table.
The first positioning mechanism and the second positioning mechanism have the same structure and both comprise: the bottom plate, fixed connection encloses into four rectangular optical axis supporting seats on the bottom plate, is equipped with the optical axis of a vertical setting on every optical axis supporting seat, and every slides on the optical axis and is equipped with the slider, set up between four sliders and with four slider fixed connection's backup pad, be equipped with the promotion in the backup pad spill loading piece and convex loading piece and fatigue steel wire in close contact with's thrustor, thrustor includes:
the loading plate is arranged on the linear guide rail in a sliding mode through a guide rail sliding block, a circular through hole is formed in the middle of the bottom plate, and a strip-shaped hole is formed in the position, located right above the circular through hole, of the rear end of the supporting plate;
one end of the nylon rope is connected with the balancing weight, the other end of the nylon rope penetrates through the circular through hole and the strip-shaped hole in sequence and then is connected with one end of the loading plate, which is far away from the fatigue steel wire, and the loading plate horizontally moves towards the fatigue steel wire on the linear guide rail under the action of the gravity of the balancing weight, wherein,
a driving mechanism in the first positioning mechanism is connected with the first door-shaped support frame through a first loading rod;
a driving mechanism in the second positioning mechanism is connected with one end of a door-shaped loading rod, the other end of the door-shaped loading rod is rotatably connected with a convex loading block through a rotating shaft, a third force sensor is fixedly connected to the bottom of the convex loading block, and the bottom of the third force sensor is slidably connected with a sliding groove in a second small bearing frame through a sliding plate.
As a preferred embodiment of the technical scheme of the invention, the fatigue steel wire rotating mechanism is a stepping motor, the fatigue steel wire pre-tensioning mechanism is an electric cylinder, and a driving shaft of the stepping motor and a driving shaft of the electric cylinder are respectively fixedly connected with the fatigue steel wire through a clamp; a displacement sensor is arranged in the electric cylinder, the displacement amplitude of the electric cylinder can be measured, and then the micro-motion amplitude of the steel wire is reduced by the displacement amplitude measured by the electric cylinder.
The torsion driving unit is a steering engine, an output rotating shaft of the steering engine is connected with a steel wire rope chuck through a connecting rod, and one end of a loading steel wire is connected to the steel wire rope chuck;
the tension loading unit is a worm gear mechanism, wherein a worm is connected with a handle and used for rotary loading; the turbine winds one end of the loading steel wire, and the loading steel wire can be wound and self-locked.
As a preferred embodiment of the technical solution of the present invention, the first force sensor and the second force sensor are tension sensors; the third force sensor is a pull and pressure sensor which can measure pull force and pressure.
The state monitoring device includes: the angle sensor 1 is arranged on the stepping motor and connected with the stepping motor 2 through a coupler and is used for monitoring the rotating angle of the fatigue steel wire 6;
the static torque sensor 4 is arranged on the vertical stepping motor and used for monitoring the torque change of the fatigue steel wire 6;
the tension sensor 25 is arranged on the electric cylinder and used for monitoring the tension change and the micro-motion amplitude of the fatigue steel wire 6;
the tension sensor is arranged between the worm gear mechanism and the door-shaped support frame and is used for monitoring tension change of the loading steel wire;
the tension and pressure sensors are arranged at the bottom of the concave loading block and used for monitoring the change of the friction force between the concave loading steel wire and the fatigue steel wire, and the tension and pressure sensors are arranged at the bottom of the convex loading block and used for monitoring the change of the friction force between the convex loading steel wire and the fatigue steel wire;
and the thermal infrared imager is arranged above the left side of the fatigue steel wire and is used for monitoring the temperature change rule of the friction and the wear of the spiral contact surface of the multi-steel wire.
The steel wire rope chuck consists of a square block 66 with a through hole and a semi-cylinder 67 with a threaded hole, and the square block 66 and the semi-cylinder 67 are screwed tightly through an inner hexagon screw 68 to clamp a steel wire.
One side of the concave loading block 40 and the convex loading block 52 is provided with a groove for embedding the loading steel wire, and the loading steel wire can rotate in the groove.
The middle part of the bottom plate is provided with a large through hole for passing through a nylon rope hung with a balancing weight.
The back ends of the supporting plate 34 and the supporting plate 48 are provided with strip-shaped holes for passing through a nylon rope hung with a balancing weight.
The invention discloses a method for detecting contact fatigue, abrasion and damage of a multi-filament spiral in a steel wire rope, which comprises the following steps:
a. the fatigue steel wire is fixed at one end of the upper clamp and at the other end of the lower clamp, the electric cylinder is used for applying the pretensioning force of the fatigue steel wire, and the pretensioning force can be measured in real time through the tension sensor.
b. One end of a loading steel wire is fixed at the center of a steel wire rope chuck, the other end of the loading steel wire is connected with a worm wheel in a worm gear mechanism by bypassing a fixed pulley, the loading steel wire is tensioned by rotating a worm gear handle, a pre-tensioning force is obtained, and the pre-tensioning force can be measured in real time through a tension sensor arranged between the worm gear mechanism and a portal support frame.
And adjusting the first rotating table and the second rotating table to enable the loading steel wires on the concave loading block and the convex loading block to keep a preset cross angle.
And moving the loading plate to enable the loading steel wire on the concave loading block to contact the fatigue steel wire, connecting the tray provided with the balance weight with a nylon wire, slowly loosening the tray, driving the loading plate to slide on the slide rail by the balance weight load through the nylon wire, and transmitting the balance weight load to the concave loading block through the first rotating table, the first loading rod, the door-shaped support frame and the threaded rod to enable the loading steel wire on the concave loading block to be in close contact with the fatigue steel wire according to a preset contact force.
And moving the loading plate to enable the loading steel wire 64 on the convex loading block 52 to contact the fatigue steel wire 6, connecting the tray 11 with the balance weight with a nylon wire, slowly loosening the tray, driving the loading plate to slide on the slide rail through the nylon wire and the balance weight load to be transmitted to the convex loading block 52 through the door-shaped loading rod 46 and the threaded rod 51, and enabling the loading steel wire on the convex loading block 52 to slide along the clamping groove 50A at the bottom of the second small bearing frame and to be in close contact with the fatigue steel wire 6 according to a preset contact force.
c. By controlling the up-and-down reciprocating motion of the electric cylinder 12, the stepping motor 2 is started to enable the fatigue steel wire 6 to generate torsional motion, and the steering engine is started to enable the loading steel wire to generate torsional motion, so that the fatigue steel wire generates stretching-rotating fretting fatigue; the up-and-down movement of the electric cylinder 12 applies alternating load to the fatigue steel wires, so that the fatigue steel wires are changed in a stretching and contracting mode within a set alternating stress range, micron-sized relative dislocation is generated between the fatigue steel wires 6 and the loading steel wires on the concave loading block 40 and the convex loading block 52, and the relative dislocation displacement among the steel wires can be obtained by reducing the proportion of a measurement value built in the electric cylinder.
The fatigue wire alternating load can be measured by a tension sensor 25;
the torsion angle of the fatigue steel wire can be measured in real time through the angle sensor 1;
the torque of the fatigue wire can be measured by a static torque sensor 4,
the friction force between the fatigue steel wire 6 and the loading steel wire is measured by a tension sensor and a pressure sensor;
opening the thermal infrared imager, and monitoring the temperature change of the frictional wear of the contact surface of the steel wire;
recording alternating load, torque, torsion angle, friction force and temperature field of the fatigue steel wire in real time, and stopping the test until the fatigue steel wire is broken due to spiral contact fretting fatigue damage;
d. changing the frequency and positive and negative rotation angle amplitude of a stepping motor, the vibration frequency and amplitude of an electric cylinder, the angles of a first rotating table and a second rotating table and the weight of a load block, and carrying out multi-steel-wire spiral contact fretting fatigue tests under the conditions of different fretting frequencies, torsion angles, fretting amplitudes, cross angle amplitudes and contact loads; under the stretching and twisting compound motion mode, one motion is fixed, and the multi-steel-wire spiral contact fretting fatigue test under the compound or single motion mode of two motion modes can be realized.
Further, the concave loading steel wires comprise two concave loading steel wires, namely a first concave loading steel wire and a second concave loading steel wire, wherein,
the concave loading block is provided with two parallel grooves for embedding the concave loading steel wire, the middle part of the first concave loading steel wire is embedded on the concave loading block, one end of the first concave loading steel wire is connected with the first torsion driving unit at one side of the first door-shaped supporting frame, and the other end of the first concave loading steel wire is connected with the first tension loading unit at the other side of the first door-shaped supporting frame;
the middle part of a second concave loading steel wire is embedded on the concave loading block, one end of the second concave loading steel wire is connected with the first tension loading unit on one side of the first portal-shaped support frame, and the other end of the second concave loading steel wire is connected with the first torsion driving unit on the other side of the first portal-shaped support frame;
the two convex loading steel wires are respectively a first convex loading steel wire and a second convex loading steel wire, wherein parallel grooves used for embedding the convex loading steel wires are formed in the convex loading block, the middle part of the first convex loading steel wire is embedded in the convex loading block, one end of the first convex loading steel wire is connected with the second torsion driving unit on one side of the second portal-shaped support frame, and the other end of the first convex loading steel wire is connected with the second tension loading unit on the other side of the second portal-shaped support frame; the middle part of the second convex loading steel wire is embedded on the convex loading block, one end of the second convex loading steel wire is connected with the second tension loading unit on one side of the second portal support frame, and the other end of the second convex loading steel wire is connected with the second torsion driving unit on the other side of the second portal support frame.
Furthermore, the rear side of the concave loading block is provided with symmetrical threaded holes, two through holes are symmetrically formed in the portal support frame corresponding to the threaded holes, a threaded rod with a nut penetrates through the through holes in the portal support frame, the horizontal position of the concave loading block is adjusted by rotating the position of the nut on the threaded rod, and different radians of the loading steel wire and the fatigue steel wire are in contact.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (8)
1. A multi-wire spiral contact fatigue, abrasion and damage detection device in a steel wire rope comprises a supporting device, wherein a fatigue steel wire is vertically arranged on the supporting device, and a fatigue steel wire rotating mechanism is arranged at one end of the fatigue steel wire and used for driving the fatigue steel wire to twist around the axis of the fatigue steel wire; the other end is equipped with tired steel wire pretension mechanism for carry out pretension force loading to tired steel wire, its characterized in that still includes:
a load wire assembly for making helical contact with the fatigue wire at an intersection angle and with a pre-stress, the load wire assembly comprising: a concave wire loading mechanism and a convex wire loading mechanism, wherein,
concave steel wire loading mechanism sets up in one side of tired steel wire, includes:
the front end of the first door-shaped support frame is provided with a concave loading block;
the two groups of first loading units are arranged on the left side and the right side of the first door-shaped supporting frame in a reverse symmetry mode, each group of first loading units comprises a first torsion driving unit and a first tension loading unit, the first torsion driving unit is connected to one end of a concave loading steel wire and used for driving one end of the concave loading steel wire to be twisted around the axis of the concave loading steel wire, the first tension loading unit is connected to the other end of the concave loading steel wire and used for applying axial tension to the concave loading steel wire, and the middle of the concave loading steel wire is in butt joint with a;
the first crossing angle adjusting mechanism is used for adjusting the crossing angle between the concave loading steel wire and the fatigue steel wire;
the first positioning mechanism is used for driving the concave loading steel wire to contact with the fatigue steel wire with certain prestress;
convex steel wire loading mechanism sets up in the opposite side of tired steel wire, includes:
the front end of the second door-shaped support frame is provided with a convex loading block;
the two groups of second loading units are arranged on the left side and the right side of the second portal supporting frame in a reverse symmetry mode, each group of second loading units comprises a second torsion driving unit which is connected to one end of the convex loading steel wire and used for driving one end of the convex loading steel wire to twist around the axis of the second torsion driving unit, and a second tensioning force loading unit which is connected to the other end of the convex loading steel wire and used for applying axial tensioning force to the convex loading steel wire, and the middle part of the convex loading steel wire is in butt joint with the convex loading block;
the second crossing angle adjusting mechanism is used for adjusting the crossing angle between the convex loading steel wire and the fatigue steel wire;
the second positioning mechanism is used for driving the convex loading steel wire to contact with the fatigue steel wire with certain prestress;
a condition monitoring device comprising:
the first force sensor is connected with the fatigue steel wire loading assembly and used for monitoring the alternating load of the fatigue steel wire in real time;
the angle sensor is connected with the fatigue steel wire loading assembly and is used for monitoring the rotation angle of the fatigue steel wire in real time;
the static torque sensor is connected with the fatigue steel wire loading assembly and is used for monitoring the torque change of the fatigue steel wire in real time;
the second force sensor is arranged between the tension loading unit and the portal support frame and used for monitoring the prestress change of the loading steel wire;
the third force sensor comprises two force sensors, one force sensor is arranged at the bottom of the concave loading block and used for monitoring the change of the friction force between the concave loading steel wire and the fatigue steel wire, and the other force sensor is arranged at the bottom of the convex loading block and used for monitoring the change of the friction force between the convex loading steel wire and the fatigue steel wire;
the thermal infrared imager monitors the temperature change of the friction wear of the contact surface of the steel wire in real time;
the first intersection angle adjusting mechanism comprises a first loading rod and a first rotating table, wherein one end of the first loading rod is fixedly connected with the rear end of the first portal-shaped supporting frame, the other end of the first loading rod is connected with the first rotating table, and a first rotating table base is fixedly connected with the first positioning mechanism;
the second intersection angle adjusting mechanism comprises a second loading rod, a fixed block and a second rotating table, wherein one end of the second loading rod is fixedly connected with the rear end of the second door-shaped supporting frame, the other end of the second loading rod is connected with the fixed block, and the fixed block is fixedly connected with the second rotating table;
the first positioning mechanism and the second positioning mechanism have the same structure and both comprise: the bottom plate, fixed connection encloses into four rectangular optical axis supporting seats on the bottom plate, is equipped with the optical axis of a vertical setting on every optical axis supporting seat, and every slides on the optical axis and is equipped with the slider, set up between four sliders and with four slider fixed connection's backup pad, be equipped with the promotion in the backup pad spill loading piece and convex loading piece and fatigue steel wire in close contact with's thrustor, thrustor includes:
the loading plate is arranged on the linear guide rail in a sliding mode through a guide rail sliding block, a circular through hole is formed in the middle of the bottom plate, and a strip-shaped hole is formed in the position, located right above the circular through hole, of the rear end of the supporting plate;
one end of the nylon rope is connected with the balancing weight, the other end of the nylon rope penetrates through the circular through hole and the strip-shaped hole in sequence and then is connected with one end of the loading plate, which is far away from the fatigue steel wire, and the loading plate horizontally moves towards the fatigue steel wire on the linear guide rail under the action of the gravity of the balancing weight, wherein,
a driving mechanism in the first positioning mechanism is connected with the first door-shaped support frame through a first loading rod;
a driving mechanism in the second positioning mechanism is connected with one end of a door-shaped loading rod, the other end of the door-shaped loading rod is rotatably connected with a convex loading block through a rotating shaft, a third force sensor is fixedly connected to the bottom of the convex loading block, and the bottom of the third force sensor is slidably connected with a sliding groove in a second small bearing frame through a sliding plate.
2. The device for detecting contact fatigue, wear and damage of the multi-filament spiral inside the steel wire rope according to claim 1, wherein a locking screw is arranged on the sliding block, so that the sliding block can be fixed at any height position of an optical axis.
3. The device for detecting the contact fatigue, the wear and the damage of the multi-wire spiral inside the steel wire rope according to claim 1, wherein the fatigue steel wire rotating mechanism is a stepping motor, the fatigue steel wire pre-tensioning mechanism is an electric cylinder, and a driving shaft of the stepping motor and a driving shaft of the electric cylinder are fixedly connected with the fatigue steel wire through a clamp respectively;
the torsion driving unit is a steering engine, an output rotating shaft of the steering engine is connected with a steel wire rope chuck through a connecting rod, and one end of a loading steel wire is connected to the steel wire rope chuck;
the tension loading unit is a worm gear mechanism, wherein a worm is connected with a handle and used for rotary loading; the turbine winds one end of the loading steel wire, and the loading steel wire can be wound and self-locked.
4. The device for detecting contact fatigue, wear and damage of the multi-filament spiral inside the steel wire rope according to claim 1, wherein the first force sensor and the second force sensor are tension sensors; the third force sensor is a pull and pressure sensor.
5. The device for detecting the contact fatigue, the wear and the damage of the multi-filament spiral inside the steel wire rope according to claim 1, wherein the supporting device comprises four bottom beams which are encircled to be rectangular, four supporting upright columns which are symmetrically arranged on the bottom beams, four reinforcing ribs are arranged at the bottom ends of the supporting upright columns, four upper bearing beams which are encircled to be rectangular are arranged at the top parts of the supporting upright columns, four bearing seat bearing beams which are encircled to be rectangular and four middle bearing beams are arranged at the middle parts of the supporting upright columns.
6. The detection method using the device for detecting the contact fatigue, the wear and the damage of the multi-filament spiral in the steel wire rope according to any one of claims 1 to 5 is characterized in that: the method comprises the following steps:
a. connecting a fatigue steel wire on the fatigue steel wire loading assembly, and measuring the pretension force of the fatigue steel wire in real time through a first force sensor;
b. the concave steel wire loading mechanism is connected with a concave loading steel wire, and the concave loading steel wire on the concave loading block keeps a preset cross angle to be in close contact with the fatigue steel wire by adjusting the first cross angle adjusting mechanism and the first positioning mechanism;
the convex loading steel wire loading mechanism is connected with a convex loading steel wire, and the convex loading steel wire on the convex loading block keeps a preset cross angle and is in close contact with the fatigue steel wire by adjusting the second cross angle adjusting mechanism and the second positioning mechanism;
the pretensioning force of the concave loading steel wire and the pretensioning force of the convex loading steel wire are measured in real time through the second force sensor;
c. controlling the fatigue steel wire torsion unit to enable the fatigue steel wire to generate torsion motion, and respectively opening torsion driving units on the concave steel wire loading mechanism and the convex steel wire loading mechanism to enable the concave loading steel wire and the convex loading steel wire to also generate torsion motion;
applying alternating load to the fatigue steel wires by controlling the fatigue steel wire pre-tensioning mechanism to enable the fatigue steel wires to be changed in a stretching and contracting mode within a set alternating stress range, and enabling the fatigue steel wires and the loading steel wires to generate micron-sized relative dislocation, wherein the relative dislocation displacement between the steel wires is obtained by reducing the proportion of a built-in measurement value of the fatigue steel wire pre-tensioning mechanism, and the multi-axis fretting fatigue phenomenon of the fatigue steel wires is realized;
measuring the alternating load of the fatigue steel wire in real time through a first force sensor;
measuring the torsion angle of the fatigue steel wire in real time through an angle sensor;
measuring the torque of the fatigue steel wire in real time through a static torque sensor;
monitoring the prestress change of the loading steel wire in real time through a second force sensor;
the friction force change between the loading steel wire and the fatigue steel wire is monitored in real time through a third force sensor
Monitoring the temperature change of the frictional wear of the contact surface of the steel wire in real time by using a thermal infrared imager;
recording alternating load, torque, torsion angle, friction force and temperature field of the fatigue steel wire in real time, and stopping the test until the fatigue steel wire is broken due to spiral contact fretting fatigue damage;
d. changing the frequency and the positive and negative rotation angle amplitude of a torsion driving unit, changing the vibration frequency and the amplitude of a fatigue steel wire pre-tensioning mechanism, adjusting a crossing angle adjusting mechanism and a positioning mechanism, and performing a multi-steel-wire spiral contact fretting fatigue test under the conditions of different fretting frequencies, torsion angles, alternating loads, fretting amplitudes, crossing angles and contact loads;
under the stretching and twisting compound motion mode, one motion is fixed, and the multi-steel-wire spiral contact fretting fatigue test under the compound or single motion mode of two motion modes can be realized.
7. The detection method using the device for detecting contact fatigue, wear, and damage of a multifilament spiral inside a steel cord according to claim 6, characterized in that: the concave loading steel wires comprise two concave loading steel wires, namely a first concave loading steel wire and a second concave loading steel wire, wherein,
the concave loading block is provided with two parallel grooves for embedding the concave loading steel wire, the middle part of the first concave loading steel wire is embedded on the concave loading block, one end of the first concave loading steel wire is connected with the first torsion driving unit at one side of the first door-shaped supporting frame, and the other end of the first concave loading steel wire is connected with the first tension loading unit at the other side of the first door-shaped supporting frame;
the middle part of a second concave loading steel wire is embedded on the concave loading block, one end of the second concave loading steel wire is connected with the first tension loading unit on one side of the first portal-shaped support frame, and the other end of the second concave loading steel wire is connected with the first torsion driving unit on the other side of the first portal-shaped support frame;
the convex loading steel wires comprise two convex loading steel wires which are respectively a first convex loading steel wire and a second convex loading steel wire, wherein,
the convex loading block is provided with parallel grooves for embedding convex loading steel wires, the middle part of the first convex loading steel wire is embedded on the convex loading block, one end of the first convex loading steel wire is connected with the second torsion driving unit at one side of the second portal-shaped support frame, and the other end of the first convex loading steel wire is connected with the second tension loading unit at the other side of the second portal-shaped support frame;
the middle part of the second convex loading steel wire is embedded on the convex loading block, one end of the second convex loading steel wire is connected with the second tension loading unit on one side of the second portal support frame, and the other end of the second convex loading steel wire is connected with the second torsion driving unit on the other side of the second portal support frame.
8. The detection method using the device for detecting contact fatigue, wear, and damage of a multifilament spiral inside a steel cord according to claim 6, characterized in that: the rear side of the concave loading block is provided with symmetrical threaded holes, two through holes are symmetrically formed in the portal support frame corresponding to the threaded holes, a threaded rod with a nut penetrates through the through holes in the portal support frame, the horizontal position of the concave loading block is adjusted by rotating the position of the nut on the threaded rod, and different radians of contact between the loading steel wire and the fatigue steel wire are achieved.
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