摘要
钢绳芯胶带运输机是目前煤矿、冶金、港口、大型化工、钢铁企业和水利工程的重要运输设备,具备运输效率高、速度快、距离长、负载重等特点。但是钢绳常常因胶带破损发生锈蚀、断丝、磨损、变形等故障,若不及时检测出来加以处理,一旦钢绳芯胶带出现断带事故,极易造成严重的经济损失和人员伤亡。当前采用超声、射线、磁粉、渗透和涡流等无损检测(Nondestructive Testing,NDT)方法对已经存在的缺陷进行检测,具有较高的检出率,但这些传统的方法NDT因方法具有设备体积大、操作复杂、对人员素质要求高等缺点,且每一种方法都又各自的局限性。金属磁记忆(Metal Magnetic Memory, MMM)检测技术[1]可以准确探测出被测对象上以应力集中区为特征的危险部件和部位,是一种新的无损检测方法,对金属构件的早期失效和寿命评估有重要意义。与传统的无损检测方法相比具有提离效应小﹑不需要磁化和清洁处理钢丝绳。
对钢绳芯胶带的检测本质上就是对钢丝绳的检测。绪论中通过对目前钢丝绳无损检测方法的概述,分析现有各种无损检测原理和检测方法的优缺点。研究现阶段对钢绳芯胶带检测的技术,现阶段无损检测方法能做到定性分析却做不到定量分析。金属磁记忆法可以做到定性分析和定量分析。所以是无损检测的新方向。
第二章是研究钢绳芯胶带的结构及运行机理。钢绳芯胶带有两种,其结构差别主要是有无帆布。钢绳芯胶带在运行中会出现各种故障,重点阐述金属磁记忆法检测钢绳芯胶带的原理。
第三章研究检测系统原理。研究测量基本要求﹑磁检测元件﹑磁测量方法﹑磁测量探头分类﹑磁电信号的时空域采样方法﹑磁电信号的解释的形式分类等基本知识。本课题选用霍尔元件作为钢绳芯胶带的磁检测元件。
第四章设计研究检测系统。钢绳芯胶带检测系统主要是探头阵列信号的采集和处理﹑上传。霍尔元件探头输出的是微弱包含干扰的电压信号,所以对其电压信号进行放大﹑滤波送到LPC2368自带A/D采集。LPC2368微控器系统通过处理﹑储存﹑显示最后上传数据到上位机。同时在LPC2368微控器上移植实时操作系统μC/OS-II,建立任务方便以后系统的修改和扩展。
第五章软件系统研究。划分任务,移植μC/OS-II系统后。首先完成系统的初始化,建立6个任务级并设计任务之间的关系,画出任务详细的流程图,最后完成用户应用程序。
第六章检测信号分析。使用检测系统采集现场钢绳芯胶带数据,对采集到的数据进行分析,判断出钢绳芯胶带现在运行的状态。
Now the steel-cord belt conveyor is the important transport equipment of the coal mine, metallurgy, ports, large-scale chemical industry, iron and steel enterprises and water conservancy projects.It has the transport characteristics of high speed,long distance,heavy load and so on.However,the steel often has the troubles of rust, broken wires, wear and deformation because of the breakage adhesive tape rope.If the troubles can not be detected and deal with in time,once the steel-cord belt happen the accidents of joint break, serious economic losses and casualties will be caused.At present,the Nondestructive Testing methods,such as ultrasound,ray,magnetic particle, infiltration and eddy current,can test the deficiencies exist,and have high detection rate.But these methods can not solve the early diagnosis problem of fatigue fracture caused by the stress concentration. On the other hand, the traditional methods of NDT have the disadvantages of bulky equipment, labor-intensive,complicated operate,and high quality requirements of operator,and each method has its own limitation. Metal Magnetic Memory detection technology can accurately detect the stress concentration zone on the target. It is a new non-destructive testing (NDT) technique. It is important on early diagnostics of fatigue damages and evaluatuion of life time.In order to check the early injury problems and hidden troubles of the steel-cord belts reliably and sensitively.It has small lifr-off effects and do not need to magnetization and cleaning.
The detection of the steel cord belt is essentially the detection of the wire rope. In the Introduction, through the summary of current methods of nondestructive testing, analyse the advantages and disadvantages of various methods of existing principles and testings.At this stage NDT method could do quantitave analysis but not do qualitative analysis.So it is the new direction of non-destructive testing.
The second chapter is to study the structure of steel cord conveyor belt and the running mechanism.There are two steel cord conveyor belt,the structural differeences mainly in the availability of canvas.Steel cord conveyor belt running in a variety of occurs,focousing on the metal magnetic memory testing steel cord conveyor belt principle.
The third chapter is to study the detection systems theory.Introduces the basic requirements meausured magnetic detection elements﹑ magnetic sorting﹑magnetic measurement probe signals in spatial samping﹑interpreation of magnetic signals in the form of classification and other basic knowledge.The topic chosen for the hall element magnetic detection elements.
Chapter IV Design detection system. Steel cord conveyor belt detection system is mainly probe array signal acquisition and handling, upload. Hall element probe output voltage signal ,so its voltage signal amplification﹑filter sent to the LPC2368 own A/D acquisition.LPC2368 microcontroller system ,through the handing,storage,display last uploaded data to the PC. At the same time,LPC2368 microcontroller migration real-time operating systemμC / OS-II, the establishment of the task to facilitate future system changes and expansion.
The fifth chapter is software system.Division of tasks,after transplant ucos-ii system. First to compltete the system,set up six task-level and design the tasks relationship,the task to draw a detailed flowed chart,the last complelet user applications.
Chapter VI detection signal analysis.Uing the detection system of data collection on-site steel cord conveyor belt.Analysis the collected data.Steel cord conveyor belt now determine the status of running .
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