基于正交试验的钢丝绳探伤仪结构参数优化

田劼; 孙钢钢; 李睿峰; 王伟

doi:10.13272/j.issn.1671-251x.2022050017

基于正交试验的钢丝绳探伤仪结构参数优化

doi: 10.13272/j.issn.1671-251x.2022050017

田劼^{1, 2,},
孙钢钢^{1, 2},
李睿峰^{1, 2},
王伟^{1, 2}

1.
中国矿业大学(北京) 机电与信息工程学院, 北京　100083
2.
中国矿业大学(北京) 煤矿智能化与机器人创新应用应急管理部重点实验室, 北京　100083

基金项目: 国家自然科学基金面上项目（51774293）；中央高校基本科研业务−重点领域交叉创新项目（2022JCCXJD02）。

详细信息

作者简介:
田劼 (1982—)，女，山西太原人，教授，博士，主要研究方向为钢丝绳无损检测，E-mail：tianj@cumtb.edu.cn

中图分类号: TD633
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出版历程
- 收稿日期: 2022-05-07
- 修回日期: 2022-08-25
- 网络出版日期: 2022-06-16

Optimization of structural parameters of wire rope flaw detector based on orthogonal test

TIAN Jie^{1, 2
,},
SUN Ganggang^{1, 2},
LI Ruifeng^{1, 2},
WANG Wei^{1, 2}

1.
School of Mechanical Electronic and Information Engineering, China University of Mining and Technology-Beijing, Beijing 100083, China
2.
Key Laboratory of Coal Mine Intelligence and Robot Innovative Application, Ministry of Emergency Management, China University of Mining and Technology-Beijing, Beijing 100083, China

摘要

摘要: 在钢丝绳损伤检测中，探伤仪结构设计对钢丝绳损伤检测精度至关重要。针对现有基于电磁的钢丝绳探伤仪各结构参数及参数各种组合研究不充分的问题，提出了一种基于正交试验的钢丝绳探伤仪结构参数优化方法。基于径向磁环磁场分布的理论数学模型和等效磁路理论模型，分析得出影响钢丝绳探伤仪检测精度的结构参数有磁铁长度、磁铁厚度、衔铁厚度、衔铁长度和倒角参数。通过正交试验方法研究了各参数之间的影响等级及影响显著性：各参数对钢丝绳探伤仪检测精度的影响等级为磁铁厚度、磁铁长度、衔铁长度、衔铁厚度和倒角情况，磁铁厚度、磁铁长度和衔铁长度影响显著，在设计钢丝绳探伤仪时应优先考虑，衔铁厚度及倒角显著性不强，可以忽略；磁铁厚度和磁铁长度（＜70 mm）的影响随着水平的增长整体呈正相关关系，随着磁铁厚度和磁铁长度的增大，检测精度会明显提升；而衔铁长度整体呈负相关关系，长度越长，检测精度越差。根据上述分析结果，确定了钢丝绳探伤仪各参数优化数值，并对优化前后的钢丝绳探伤仪的磁力线分布、磁场分布及径向、轴向各相位磁感应强度的分布进行对比验证。结果表明：基于正交试验优化后的钢丝绳探伤仪，磁力线分布均匀，对钢丝绳的励磁效果达到2 T以上，漏磁信号明显，不同相位下的损伤信号区别较大；与优化前的钢丝绳探伤仪相比具有磁感应强度大幅度提高、空域分布明显改善、对传感器位置（提离值）的要求相对宽泛的优势，径向检测精度提升了40%左右，轴向检测精度提高约80%，对钢丝绳损伤的感知效果明显提升。
- 矿井提升机 /
- 钢丝绳探伤仪 /
- 无损检测 /
- 结构参数优化 /
- 漏磁检测 /
- 磁感应强度 /
- 正交试验
Abstract: In the detection of wire rope damage, the structure design of the flaw detector is very important to the detection precision of wire rope damage. The research on the structural parameters and their combinations of the existing electromagnetic wire rope flaw detector is insufficient. In order to solve the above problems, an optimization method of structural parameters of wire rope flaw detector based on orthogonal test is proposed. Based on the theoretical mathematical model of magnetic field distribution of radial magnetic ring and the theoretical model of the equivalent magnetic circuit, the structural parameters affecting the detection precision of wire rope flaw detector are analyzed and obtained. The parameters include the length of the magnet, the thickness of the magnet, the thickness of the armature, the length of the armature and the chamfer parameter. The influence grade and significance of each parameter are studied by the orthogonal test. The influence grade of each parameter factor on the detection precision of the wire rope flaw detector is the thickness of the magnet, the length of the magnet, the length of the armature, the thickness of the armature and the chamfer. The thickness of the magnet, the length of the magnet and the length of the armature have significant effects. These should be given priority when designing the wire rope flaw detector. The thickness of the armature and the chamfer are not significant and can be ignored. The influence of the thickness of the magnet and the length of the magnet is positively correlated with the increase of level. With the increase of the thickness of the magnet and the length (＜70 mm) of the magnet, the detection precision will be significantly improved. The length of the armature shows a negative correlation trend as a whole. The longer the length, the worse the detection precision. According to the analysis results, the optimized values of the parameters of the steel wire rope flaw detector are determined. The magnetic line distribution, the magnetic field distribution and the radial and axial phase magnetic induction intensity distribution of the steel wire rope flaw detector before and after the optimization are compared and verified. The results show that the optimized steel wire rope flaw detector based on the orthogonal test has uniform magnetic flux distribution. The excitation effect of steel wire rope is more than 2 T. The magnetic flux leakage signal is obvious. The damage signal under different phases is quite different. Compared with the steel wire rope flaw detector before optimization, the steel wire rope flaw detector has the following advantages. The magnetic flux leakage intensity is greatly improved. The spatial distribution is obviously improved. The requirements for the position (lift-off value) of the sensor are relatively broad. The radial detection precision is improved by about 40%, and the axial detection precision is improved by about 80%. The perception effect on the damage of the steel wire rope is obviously improved.
- mine hoist /
- wire rope flaw detector /
- non-destructive testing /
- structural parameters optimization /
- magnetic flux leakage detection /
- magnetic induction intensity /
- orthogonal test

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图 1 钢丝绳探伤原理

Figure 1. Wire rope flaw detection principle

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图 2 单个和组合磁铁励磁环结构简图

Figure 2. The structure of single and combined permanent magnet excitation ring

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图 3 钢丝绳探伤仪等效电路模型

Figure 3. Equivalent circuit model of wire rope flaw detector

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图 4 钢丝绳探伤仪结构参数

Figure 4. Structure parameters of wire rope flaw detector

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图 5 损伤程度随各水平的变化趋势

Figure 5. Change trends of damage degree with different levels

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图 6 优化后模型磁场分布

Figure 6. Magnetic field distribution of the optimized model

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图 7 周向八相位磁感应强度分布及各相位损伤程度分布

Figure 7. Circumferential 8-phase magnetic induction intensity distribution and phase damage distribution

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图 8 优化前后钢丝绳探伤仪竖直面磁感应强度云图

Figure 8. Magnetic induction intensity cloud chart of vertical plane before and after optimization of wire rope flaw detector

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图 9 优化前后钢丝绳探伤仪截面磁感应强度云图

Figure 9. Magnetic induction intensity cloud chart of section before and after optimization of wire rope flaw detector

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图 10 径向漏磁比较

Figure 10. Comparison of radial magnetic flux leakage

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图 11 轴向漏磁比较

Figure 11. Comparison of axial magnetic flux leakage

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表 1 正交试验的因素水平情况

Table 1. Factors level of orthogonal test

水平序号	影响因素
水平序号	L_c/mm	H_c/mm	H_x/mm	L_x/mm	C	O
1	40	10	3	180	无倒角
2	50	15	6	200	倒直角
3	60	20	9	220	倒圆角
4	70	25	12	240
5	80	30	15	260

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表 2 参数水平组合正交表及损伤程度结果

Table 2. Parameter level combination orthogonal table and damage degree results

试验编号	L_c	H_c	H_x	L_x	C	O	损伤程度/mT
1	1	1	1	1	1	1	26.587144
2	1	2	3	4	3	2	10.624048
3	1	3	5	2	3	3	28.355586
4	1	4	2	5	3	4	26.593358
5	1	5	4	3	2	5	47.330237
6	2	1	5	4	3	5	23.039064
7	2	2	2	2	2	1	48.707213
8	2	3	4	5	1	2	15.770268
9	2	4	1	3	3	3	68.412631
10	2	5	3	1	3	4	138.419259
11	3	1	4	2	3	4	44.946268
12	3	2	1	5	3	5	33.241197
13	3	3	3	3	3	1	57.955367
14	3	4	5	1	2	2	120.399325
15	3	5	2	4	1	3	119.761092
16	4	1	3	5	2	3	13.986221
17	4	2	5	3	1	4	56.378326
18	4	3	2	1	3	5	100.852858
19	4	4	4	4	3	1	145.954792
20	4	5	1	2	3	2	165.448759
21	5	1	2	3	3	2	45.312620
22	5	2	4	1	3	3	69.860399
23	5	3	1	4	2	4	67.972814
24	5	4	3	2	1	5	112.335923
25	5	5	5	5	3	1	73.373379

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表 3 影响钢丝绳探伤仪检测精度的因素极差分析

Table 3. Range analysis of factors affecting detection precision of wire rope detector

极差分析项		影响因素
极差分析项		L_c	H_c	H_x	L_x	C	O
水平值的总值	$ {T_{i1}} $	139.490372	153.871317	361.662544	456.118983	330.832752	352.577894
	$ {T_{i2}} $	294.348435	218.811184	341.227140	399.793749	298.395810	357.555021
	$ {T_{i3}} $	376.303249	270.906893	333.320818	275.389181	1032.389583	300.375928
	$ {T_{i4}} $	482.620955	473.696028	323.861964	367.351810	0	334.310025
	$ {T_{i5}} $	368.855135	544.332730	301.545679	162.964423	0	316.799280
水平均值	$ {\overline K_{i1}} $	27.898075	30.774263	72.332509	91.223797	66.166551	70.515579
	$ {\overline K_{i2}} $	58.869687	43.762237	68.245428	79.958750	59.679162	71.511004
	$ {\overline K_{i3}} $	75.260650	54.181379	66.664164	55.077836	68.825972	60.075186
	$ {\overline K_{i4}} $	96.524191	94.739206	64.772393	73.470362	0	66.862005
	$ {\overline K_{i5}} $	73.771027	108.866545	60.309136	32.592885	0	63.359856
极差值	$ \varDelta $	68.626125	78.092282	12.023373	58.630912	9.146810	11.435819

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表 4 影响钢丝绳探伤仪检测精度因素的方差分析

Table 4. Variance analysis of factors affecting detection precision of wire rope detector

因素	离差平方和	自由度	均方值	f 值	P 值	显著性
L_c	12896.964836	4	3224.241209	15.093398	0.01	显著
H_c	22687.266077	4	5671.816519	26.551049	0	显著
H_x	391.984165	4	97.996041	0.458742	0.77	不显著
L_x	10605.710437	4	2651.427609	12.411929	0.02	显著
C	314.296186	2	157.148093	0.735646	0.53	不显著
O	462.493044	4	115.623261	—	—	—
误差	—	6	213.619302	—	—	—

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