Design and simulation analysis of a dual-source magnetic loop structure for mining steel wire rope
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摘要: 目前矿用钢丝绳损伤电磁检测方法存在主磁通检测对于局部类损伤检测精度较低，基于漏磁的局部损伤检测的定量精度不高等问题。提出了一种同时检测主磁通和漏磁的矿用钢丝绳双源磁检测方法，结合主磁通与漏磁在局部损伤检测方面的互补性，设计了双源磁检测环形筒状励磁回路和独立分离励磁回路方案。基于有限元仿真验证了2种方案的可行性，确定了以独立分离回路作为磁回路的基本结构。研究了衔铁参数、磁铁参数对磁化效果的影响和磁桥路结构参数对磁场分布的影响。结果表明：① 磁化幅值与回路数量呈正相关，与衔铁长度呈负相关，高度对磁化效果几乎没有影响。② 磁化幅值与永磁铁材料牌号、长度和厚度呈正相关，与提离值呈负相关。③ 磁化幅值与磁桥路厚度呈正相关，与空气间隙呈负相关，而提离值对磁化效果影响较小。④ 磁桥的空气间隙对磁桥路内磁通密度分布的影响较大。Abstract: Currently, the electromagnetic detection methods for mining steel wire ropes have limitations: the main flux detection method has low accuracy in detecting local damage, while magnetic leakage-based detection methods have limited quantitative accuracy in local damage assessment. A dual-source magnetic detection method was proposed to simultaneously detect both the main flux and magnetic leakage in mining steel wire ropes, leveraging the complementary strengths of these two methods in local damage detection. Two excitation loop designs were proposed: a double-source ring-shaped tubular excitation loop and an independent separation excitation loop. Finite element simulation was used to verify the feasibility of the two schemes, and the independent separation loop was chosen as the basic structure of the magnetic circuit. The effects of various armature parameters, such as size and magnet properties, on the magnetization performance were studied, as well as the influence of the magnetic bridge structure parameters on the magnetic field distribution. The results indicated that:① The magnetization amplitude was positively correlated with the number of loops and negatively correlated with the armature length, while the height had almost no effect on the magnetization performance; ② The magnetization amplitude was positively correlated with the material grade, length, and thickness, and negatively correlated with the lift-off distance; ③ The magnetization amplitude was positively correlated with thickness, negatively correlated with air gap size, while lift-off distance had little effect on the magnetization performance; ④ The air gap of the magnetic bridge significantly influenced the magnetic flux density distribution within the bridge circuit.
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图 2 双源磁检测环形筒状励磁回路
Figure 2. Ring-shaped tubular excitation loop in dual-source magnetic detection
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图 3 双源磁检测独立分离励磁回路
Figure 3. Independent separation magnetic circuit in dual-source magnetic detection
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图 5 磁感应强度云图和钢丝绳内部磁感应强度
Figure 5. Magnetic induction intensity contour plot and internal magnetic induction intensity of steel wire rope
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图 6 环形筒状励磁回路的磁通密度分布
Figure 6. Magnetic flux density distribution of ring-shaped tubular excitation loop
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图 10 环形磁铁理想和实际充磁效果
Figure 10. Ideal and actual magnetization effects of ring-shaped magnet
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图 12 钢丝绳和磁铁的磁感应强度
Figure 12. Magnetic induction intensity of steel wire ropes and magnets
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图 13 独立分离励磁回路的磁桥路磁通密度
Figure 13. Bridge magnetic flux density of independent separation magnetic loop
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图 15 回路个数变化时钢丝绳磁化强度变化情况
Figure 15. Variation of magnetization intensity in steel wire rope with changes in the number of loops
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图 17 衔铁长度变化时钢丝绳磁化强度变化情况
Figure 17. Variation of magnetization intensity in steel wire rope with changes in armature length
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图 18 不同衔铁长度的背景磁场分布情况
Figure 18. Background magnetic field distribution for different armature lengths
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图 20 衔铁厚度变化时钢丝绳磁化强度变化情况
Figure 20. Variation of magnetization intensity in steel wire rope with changes in armature thickness
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图 21 侧衔铁高度变化时钢丝绳磁化强度变化情况
Figure 21. Variation of magnetization intensity in steel wire rope with changes in side armature height
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图 22 衔铁宽度变化时钢丝绳磁化强度变化情况
Figure 22. Variation of magnetization intensity in steel wire rope with changes in armature width
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图 23 磁铁牌号变化时钢丝绳磁化强度变化情况
Figure 23. Variation of magnetization intensity in steel wire rope with changes in magnetic grade
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图 24 永磁铁长度变化时钢丝绳磁化强度变化情况
Figure 24. Variation of magnetization intensity in steel wire rope with changes in magnet length
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图 25 永磁铁厚度变化时钢丝绳磁化强度变化情况
Figure 25. Variation of magnetization intensity in steel wire rope with changes in magnet thickness
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图 26 永磁铁提离值变化时钢丝绳磁化强度变化情况
Figure 26. Variation of magnetization intensity in steel wire rope with changes in magnet lift-off value
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图 27 磁桥路提离值变化时磁通密度变化情况
Figure 27. Variation of magnetic flux density with changes in bridge circuit lift-off value
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图 28 不同提离值下磁力线分布
Figure 28. Distribution of magnetic field lines under different lift-off value
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图 29 磁桥路厚度变化时磁通密度变化情况
Figure 29. Variation of magnetic flux density with changes in bridge circuit thickness
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图 30 磁桥路空气隙变化时磁通密度变化情况
Figure 30. Variation of magnetic flux density with changes in bridge circuit air gap
表 1 不同牌号钕铁硼永磁铁参数
Table 1 Parameters of NdFeB magnets of different brands
牌号 剩磁/T 内禀矫顽力/(kA·m−1) 磁能积/(kJ·m3) N35 1.17～1.22 955 263～287 N38 1.22～1.25 955 287～310 N40 1.25～1.28 955 302～326 N42 1.28～1.32 955 318～342 N45 1.32～1.38 955 342～366 N48 1.38～1.42 955 366～390 N50 1.40～1.45 955 382～406 N52 1.43～1.48 955 398～422 
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