基于霍尔传感器的电梯钢丝绳断丝无损检测系统

摘要:

在电梯牵引系统高动态、强电磁干扰的复杂工况下,钢丝绳断丝的早期无损检测长期面临励磁磁场空间分布不均、多源信号异步采集导致的特征混叠,以及簇状与内部断丝因漏磁场衰减与叠加效应难以定量解耦等瓶颈。为此,设计基于霍尔传感器的电梯钢丝绳断丝无损检测系统。通过构建周向八回路永磁励磁结构,实现钢丝绳截面均匀深度磁化；采用分布式Senis 3轴霍尔传感器阵列与USB2884同步采集卡,完成漏磁、振动等多物理场信号的高精度同步采集与融合。将断丝漏磁场等效为磁偶极对,引入穿透修正因子与传感器有效检测面积约束,建立了磁感应强度与霍尔电势的定量映射模型,从而实现对簇状断丝与内部断丝的精准识别与分类。实验表明,系统对表面断丝的磁感应强度检测灵敏度达140×10?? T,在单根、邻近、周向多处及内部断丝等多种缺陷形态下,漏磁通峰值个数及信号特征均与理论模型一致,验证了该系统在复杂环境下具备高灵敏度、强抗干扰性与良好的集成化性能。

Abstract:

Under the complex operating conditions of high dynamics and strong electromagnetic interference in elevator traction systems, early non-destructive testing of broken wires in steel wire ropes has long faced bottlenecks such as uneven spatial distribution of the excitation magnetic field, feature aliasing caused by asynchronous acquisition of multi-source signals, and difficulties in quantitative decoupling of clustered and internal broken wires due to the attenuation and superposition effects of leakage magnetic fields. To address these issues, a non-destructive testing system for broken wires in elevator steel wire ropes based on Hall sensors is designed. By constructing a circumferential eight-loop permanent magnet excitation structure, uniform deep magnetization of the steel wire rope cross-section is achieved. A distributed Senis 3-axis Hall sensor array and a USB2884 synchronous acquisition card are employed to accomplish high-precision synchronous acquisition and fusion of multi-physical field signals, including leakage magnetic fields and vibrations. The leakage magnetic field of broken wires is equivalent to a magnetic dipole pair. By introducing a penetration correction factor and constraints on the effective detection area of the sensor, a quantitative mapping model between magnetic induction intensity and Hall potential is established, enabling precise identification and classification of clustered and internal broken wires. Experimental results demonstrate that the system achieves a detection sensitivity of 140×10?? T for the magnetic induction intensity of surface broken wires. Under various defect morphologies, including single, adjacent, multiple circumferential, and internal broken wires, the number of peak values of leakage magnetic flux and signal characteristics are consistent with the theoretical model, validating the system"s high sensitivity, strong anti-interference capability, and good integration performance in complex environments.