摘要
钢索具有高抗拉、低抗弯和低抗剪等优点，被广泛应用于特种设备、市政工程等领域，例如斜拉索、客运索道与电梯用钢丝绳以及各种起重设备吊索等等。作为上述生命线工程结构中的重要承力部件，钢索健康状况直接影响整体结构的运行安全和使用寿命。由于受力状态复杂与服役环境多样，钢索易因缺陷损伤累积或应力超限等因素而发生失效，导致重大事故和损失。因此，发展新型钢索缺陷与拉力综合检测技术，具有重要的社会意义和经济价值。
本文基于铁磁性材料的磁致伸缩与磁弹效应基本理论，发展钢索缺陷检测与拉力测量一体化传感器技术。首先，建立传感器幅频特性曲线计算模型，并结合电磁场有限元仿真方法对一体化传感器的结构参数与工作参数进行优化选取；其次，采用柔性印刷电路技术改进传感器线圈结构，提升传感器的检测及实用化性能；最终，将研制的一体化传感器用于钢索中纵向模态超声导波衰减特性研究，以及钢索断丝缺陷检测与拉力测量。本文从检测机理、传感器优化设计及试验研究等三方面对钢索的缺陷与拉力检测技术进行了系统研究，主要研究内容包括：
(1)建立了考虑电-磁-声场耦合的磁致伸缩传感器幅频特性分析计算模型。以圆电流及多段式感应线圈内部磁场分布计算为基础，分析得出线圈结构参数对磁致伸缩传感器激励与接收性能的影响规律。基于权值与相位叠加原理，采用信号仿真方法计算得出激励与接收传感器的幅频特性曲线，为磁致伸缩传感器的参数设计提供了基础依据。
(2)研制出具有优良性能，覆盖高、低频段的柔性印刷线圈式磁致伸缩传感器。基于柔性印刷电路技术，设计出具有轻、薄等特点的柔性印刷感应线圈，可卷曲安装于钢索表面，拆装便捷且激励与接收性能提升。试验测试结果表明，基于柔性印刷线圈的磁致伸缩传感器工作频率可覆盖几十千赫兹至兆赫兹范围。
(3)设计并实现了一种双模式一体化传感器，并对其进行工作参数优化。研制出一款集缺陷检测与拉力测量双功能的一体化传感器，可工作于磁致伸缩与磁弹传感器双模式，基于超声导波技术实现缺陷检测，基于磁弹法进行拉力测量。以能量转换效率和拉力测量灵敏度为优化指标，对一体化传感器的静态偏置磁路进行了优化。
(4)试验观察到轴向静载作用下钢索中L(0,1)模态的频带缺失与频带漂移现象。利用研制的一体化传感器对轴向拉伸状态下的7芯钢绞线、型号6×19S-FC钢索进行检测，观察到L(0,1)模态在70kHz附近出现频带缺失现象，且缺失频带中心频率随拉力增加而上升；在型号为6×29FI+IWR钢索中L(0,1)模态的频带能量随拉力增加从100kHz附近向30kHz附近漂移。
(5)一体化传感器的缺陷与拉力检测性能标定。利用研制的一体化传感器工作于磁致伸缩传感器模式进行钢索断丝缺陷检测，试验结果显示4根断丝缺陷处的反射回波可被传感器接收，2m范围内存在的4处断丝缺陷回波信号也可被检测到；工作于磁弹传感器模式时，对7芯钢绞线的最小应力检测分辨率小于10MPa。
Steel wire rope is commonly used in special equipments and civil engineeringsfor its superior property of high tensile strength and poor performance in bending andshear. The application examples of wire rope include the cable in suspension bridgeand passenger ropeway, the hoist wire rope in lift and elevator, etc. The wire ropesserve as the most important bearing parts in the structures, their health conditiondirectly affect the operation safety and service life of the whole structure. Corrosionsor fractured wires occurred in the wire rope due to the complexity in stress state anddiversity of service environment may result in a reduction in the load-carryingcapacity of the structure that can lead to collapse even major accidents and loss.Therefore, the development of new integrated techniques for defect detection andtension measurement of the wire rope has significant social and economic value.
This paper is dedicated to the development of integrated sensor technology forwire rope defect detection and tension measurement based on the magnetostrictiveand elastomagnetic effect of ferromagnetic material. First, the computational modelfor revealing the amplitude-frequency characteristic of the magnetostrictive sensor(MsS) is established.This computational model together with the electromagnetic fieldfinite element simulation method is applied for the optimization of the structural andworking parameters of the integrated sensor. Second, an innovative flexible printedcoil (FPC) is designed and manufactured for the MsS to replace the traditional hardsolenoid coil and enhance the performace in exciting and receiving guide wave energy.Finally, the proposed integrated sensor is applied for experimental study on theattenuation characteristics of longitudinal guided waves in wire rope, detecting defectsand measuring tension level of the wire rope. This paper focuses on the detectionmechanism analysis, optimal sensor design and experimental research on theinspection techniques for wire rope health monitor, the main research contentsinclude:
(1) A computational model for revealing the amplitude-frequency characteristicof the MsS is established in consideration of the coupling between electromagneticfield and ultrasonic waves. The influence of the sensor structure parameters on theexcitation and receiving performance of MsS is analyzed through the computation ofmagnetic field distribution inside the circular electric current and multiple groups ofsensing coil. Then, the amplitude-frequency characteristic curves of the transmitterand receiver MsS are derived from the signals that are simulated based on weight andphase superposition principle. The obtained conclusions provide fundamental basisfor the parameters design of the MsS.
(2) An innovative flexible printed coil-based MsS with superior performances is designed for the application in the high and low frequency range. The flexible printedsensing coil is embedded into a light and thin film which can be wrapped onto thewire rope surface, so that the FPC can be easily installed onto and dismounting fromthe rope. The experimental results show the FPC has superior detection performanceand its working frequency can reach from tens of kilohertz to megahertz range.
(3) An integrated sensor with dual mode is designed and its working parametersare optimized. The integrated sensor can work on dual mode of MsS andelastomagnetic sensor (EMS) with functions of both defects detection and tensionmeasurement. The sensor can detect the defect in the rope based on guided wavetechniques and measure the tension based on the elastomagnetic method. In addition,the bias magnetic circuit of the integrated sensor is optimized in consideration of boththe energy conversion efficiency and the tension measuring sensitivity of the sensor.
(4) The phenomena of frequency band missing and shifting of L (0,1) mode inwire rope under tension loading are observed. The developed integrated sensor in thispaper is used to measure the notch frequency band of L(0,1) mode in seven-wire steelstrands and6×19S-FC wire ropes, the measured central frequency of the notchfrequency band is around70kHz and it increases as the increase of tension force. Thespectrum energy of the L(0,1) mode in a6×29FI+IWR wire rope will shift from100kHz to30kHz when the tension force is increased.
(5) The performances on defect detection and tension measurement of theintegrated sensor are calibrated. First, the integrated sensor works on the MsS mode todetect the broken wire flaws in the wire rope. The experimental results show that theMsS can receive the signal reflected from four broken wires and successfully detectthe four broken-wire flaws that locate apart from the sensor less than two meters.Second, the integrated sensor works on the EMS mode to be applied for tensionmeasurement in wire rope. The experimental results obtained from a seven-wire steelstrand shows that the stress measurement resolution of the sensor is less than10MPa.
引文
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