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From Materials Evaluation, Vol. 75, No. 4, pp: 501-500.
Copyright © 2017 The American Society for Nondestructive Testing, Inc.
ABSTRACT: Introduction
Hoist wire ropes often operate in a high-speed Hoist wire ropes are vital components of safety and produc-
swing status, and they are beyond the capability of tion that operate in high-speed swaying conditions; therefore,
present portable magnet magnetic flux leakage monitoring by NDT (nondestructive testing) methods is
urgently demanded for their structural health (Chaplin, 1995;
(MFL) sensors based on the yoke magnetic method
Schrems et al., 1997). The wire ropes are driven by a friction
due to its strong magnetic force and large weight. wheel and run in turning motion with the aid of a guide
Unlike the yoke method, an open permanent wheel, and then the dragging cages move up and down in a
magnetization method is proposed by theoretical common mine shaft. Owing to the spindle and soft features of
the ropes themselves (maximum length: 3000 m), high-speed
analyses and also verified by the finite element
(maximum speed:15 m/s) swaying, and non-uniform loading,
method (FEM) and experiments. An open random shaking is frequent in the operational ropes with a
permanent magnetization method features much large distance (maximum: 50 mm) from detection sensors.
weaker magnetic interaction force and similar For the running characters described above, there are some
key challenges that should be addressed during the portable
magnetization capability compared to the tradi-
NDT for wire ropes. For instance, the swaying interaction
tional yoke method. Meanwhile, the relevant between tested ropes and detectors is usually small or weak,
detection sensor for wire rope is designed by simu- and therefore the detectors must be capable of self-adaptively
lation optimization to further test the prepon- tracking the swaying ropes to maintain a constant lift-off
between tested wire ropes and sensing units, guaranteeing a
derant features. Furthermore, experimental
good magnetic signal-to-noise rate. Additionally, the poor
comparisons between the open and yoke sensors working conditions require the whole NDT process for
for wire rope inspection were also conducted, portable wire ropes to be accomplished automatically instead
which successfully confirmed the characterization of manually.
Because of the powerful detection ability particularly for
of smaller magnetic interaction force and less wear
inner defects, the MFL (magnetic flux leakage) approach has
and damage in contrast with traditional technolo- been widely used for wire ropes detection (Callan et al., 1959;
gies. Finally, the corresponding MFL apparatus was Basak, 2005). However, all the MFL testing instruments for
developed and applied, which demonstrated the wire ropes are simply portable styles based on yoke-magneti-
zation method, and can’t be applied to high-speed inspections
good practicability for the nondestructive testing
due to the wear damages and shaking magnetic noises caused
of hoist ropes under poor working conditions. by great magnetic interaction force, large weight, or swing
KEYWORDS: open magnetization, nondestructive inertia of the magnetic yoke structures (Hirama et al., 1984;
testing (NDT), magnetic flux leakage (MFL), Nishiyori et al., 2013; Yoshioka et al., 2011; Osada et al.
2007). With respect to the portable MFL technology for static
magnetic yoke, hoist wire ropes
defect testing of wire ropes, much attention has been focused
on the influence element analyses of yoke magnetization
method, design optimization of yoke configuration, and engi-
neering applications of magnet yoke MFL sensors under the
*School of Mechanical Science & Engineering, Huazhong University of framework of magnetic yoke method. For instance, another
Science and Technology, Wuhan, 430074 China; e-mail address: author (Mitsuaki et al., 2003) carried out the numerical
yhsun@hust.edu.cn.
† School of Mechanical Science & Engineering, Huazhong University of analyses of the magnetization status for objects or the excita-
Science and Technology, Wuhan, 430074 China tion effect for defect and detection parameters, which may
(at least 300 N) with the ropes, large length (at least 240 mm),
stack magnets, the air gap lift-distance of the permanent sensor is characterized by strong magnetic force interaction
magnetic polar, and the size of the magnetic yoke. Another
author (Radovanović et al., 2012) presented some applica- large weight (at least 9 kg), and poor adaptability for tested
tions of magnetic yoke method, such as magnetization for the wire ropes with different diameters. Consequently, with
hoist wire ropes and bridge cables detection. respect to the portable mine hoist wire ropes running in a
To address the hoist wire rope inspection challenges, this high speed swaying status, the existing magnetic yoke method
paper aims to present the advantages of an open magnetiza- is ill-suited for hoist wire rope detection.
tion sensor over the yoke magnetization method in terms of Differing from the magnetic circuit principles mentioned
magnetic excitation capability and magnetic interaction force. above, an open magnetization method created by a ring-
Furthermore, this paper also intends to design a relevant shaped magnet contrasts with the commonly used ring-
detection sensor based on open permanent magnetization shaped coils, which apply open magnetization technique to
method by optimization and a testing probe configuration magnetize the detected objects. According to magnetic charge
capable of tracking swing rope by experimental comparison of and molecular flow theory, the description for the magnetic
MFL signal change trends. Finally, this paper develops a potential fm at an arbitrary point of the space V outside the
corresponding portable testing apparatus with great promise permanent is:
of application performance in the future. 1 M( s) × n(s) 1 ∇ × M( s)
(1) φm = Ñ∫ dS + ∫ dV
4π S r−s 4π V r − s
Detection Principles Based on Open Magnetization
Method where
Presently, the commonly used portable MFL testing instru- M(s) is the magnetization vector and n(s) is the external
ment for static wire rope defect detection mainly consists of surface normal one,
several magnetic-yoke testing packages. Each of them is s is the position vector for the source point of magnet,
composed of double permanent magnet stacks with magnetic r is the position vector for the field point,
poles facing the tested object, ferrous yoke connecting the and ∇ is divergence operator.
stacks, and magnetic sensing units fixed under the yoke and
adjacent to the poles. The magnetic-yoke MFL testing Owing to the uniform magnetization, the ring-shaped
method for wire rope is schematically illustrated in Figure 1. magnet manifests itself by surface current and features no
To magnetically saturate the object being detected, the body current. Therefore, there is equivalent electric current
double magnetic poles should be located closely to the tested density for an area of rsm = M(s) × n(s) and for a volume of
wire rope as much as possible, together with the sensing units, rm = ∇ × M(s) = 0.
leading to a small lift-off distance (1 to 5 mm) for each package Thus, Equation 1 can be:
relative to the tested wire rope. Additionally, the ferrous yoke 1 ρsm
should also be designed at a certain length (over 240 mm) (2) φm = Ñ∫ dS
4π S r − s
and height (over 50 mm) to ensure a linear working range for
H (ρ , φ , h ') =
M
∫∫
(ρ − x ) i + yj + ( h '− z) k dS −
decreased. Consequently, the full circumference magnetizer is
4 π S+ 3 like a tubular coil with excitation current, as shown in Figure
((ρ − x ) + y
2 2
+ ( h '− z) )
2 2
2b; the ring-shaped magnetizer can be designed with larger
space inside for separately disposing the magnetic sensing
(4) M
∫∫
(ρ − x ) i + yj + ( h '− z)k dS units with various sizes corresponding to different wire ropes.
4 π S− 3
((ρ − x) + y + (h'− z) )
2 2 2 2 As a result, the provided method has the advantage of small
magnetic force interactions with the tested ropes, simple
configuration for realization, and all-purpose magnetizer char-
Where, the variable h’ is the z-coordinate of an arbitrary acteristics for various sized wire ropes.
point. Furthermore, the magnetic field strength produced by
the ring-shaped magnet can be obtained by vector sum, Comparative Analyses Between Open and Yoke Method
described as: by FEM
Finite element method (FEM) was applied to simulate and
(5) H (ρ , ϕ , h ')S
+ −S−
( ) (
= H ρS+ , ϕ , h ' − H ρS− , ϕ , h ' ) analyze the comparisons, and the two magnetization methods
presented above were modeled for the same steel wire rope
Where, the S+ and S- represent the positive and negative (rope diameter 32 mm and length 300 mm, dextral rope strand
magnetic source field at the arbitrary point, respectively. number 19) with a broken wire (discontinuity diameter 1.2 mm).
Finally, the magnetic flux density in the magnetized body The two models consist of a ring-shaped permanent magnet
(relative magnetic permeability m) provided by the open (axial length 80 mm, internal diameter 70 mm, and external
magnetization method can be calculated as: diameter 100 mm) as an open magnetizer and six magnet
yokes (width 24 mm, height 20 mm, length 180 mm, leg
(6) B (ρ , φ , h ') = µ × H (ρ , φ , h ') length 10 mm, leg spacing 100 mm, lift-off 8 mm) as a yoke
magnetizer, respectively. In the former model, to ensure the
Unlike the above-mentioned conventional magnetic yoke versatility of an open magnetizer for different sized wire ropes,
method, a new ring-shaped MFL testing method is proposed radial spacing should be somewhat larger, and the size of 20 mm
here, as displayed in Figure 2, that learns from the widespread is selected here. Based on practice application experience,
Z
P(ρ,Φ, z)
Ring-shaped magnet
Z1+h
Magnetic
sensing unit
Z1
Wire rope
Z1–h
Defect
(a) R ρ (b)
Figure 2. Testing principles based on open magnetizing method: (a) unattached magnetic sensing units placed inside the ring magnet; and
(b) full circumference magnetizer.
(a) (b)
Figure 3. Finite element method models: (a) open method; and (b) yoke method.
Ring-shaped magnet
(a)
0.5 0.5
0.8 0.8
1.0 1.0
1.2 1.2
1.5 1.5
1.8 1.8
2.0 2.0
2.3 2.3
Figure 4. Magnetization capabilities for wire ropes provided by: (a) open method; and (b) yoke method.
Figure 5. Magnetic interaction forces caused by: (a) open model; and (b) yoke model. O, X, Y, and Z = Cartesian coordinates.
a certain length (60 mm) of the middle of the ring-shaped objects has a great influence on the service life of both sensors
magnet is replaced by a ferrous ring-shaped configuration and tested objects due to wear or impact damage. Addition-
with the same size, either for the installation convenience of ally, a large magnetic interaction force also affects the steady
magnetic sensing units or for the reduction of cost. During the location in the center of the magnetizer and the quick
course of the simulations, the coercive force and relative response for detaching the sensor from the tested object.
magnetic permeability of permanent magnets made of NdFeB These problems are apparent in the portable inspections for
material were respectively 490 000 A/M and 1 and all the the elongated objects in service. Therefore, the magnetic
ferrous materials had the magnetic permeability based on interaction force brought out by relevant methods should be
a B-H curve. The finite element chosen was Solid236, a considered. Since MFL sensors are usually designed in two
3-D 20-node element which is applicable to 3-D static electro- half parts to encircle the tested objects, the magnetic interac-
magnetic analyses and to modeling air, iron, nonferrous mate- tion force generated by the double half structures of both
rials, and permanent magnets. Additionally, Solid236 can be magnetization methods was extracted by vector plot of
used with command macros such as EMAGERR (Electro- magnetic force (FMAG), as shown in Figure 5.
magnetic Relative Error) for calculating relative error and Furthermore, the detailed value of magnetic forces were
EMFT (Electromagnetic Forces and Torques) for summa- calculated and summarized by directly using the command
rizing electromagnetic forces. Two finite element models stream of FEM tool ANSYS of EMFT, and the forces were
were obtained by the usage of sweep mesh combined with stored as items Fx, Fy, Fz, Ftotal parameters, as shown in Table 1.
free mesh for both high resolution and fast computation, as Where the items of Fx, Fy, and Fz are the magnetic force
presented in Figures 3a and 3b, respectively. component in Cartesian coordinate system in Table 1, and
After solving the finite element models designed above, Ftotal is the vector sum magnetic force of these components.
magnetization results of magnetic flux density B in tesla for Figure 5 and Table 1 demonstrate that the magnetic inter-
the steel wire ropes were obtained, as displayed in Figure 4. In action force produced by the yoke magnetization method is
Figures 4a and 4b, it can be observed that both of the
methods produce the similar magnetic flux density at the TABLE 1
magnetizing center of the wire ropes and they are capable of Summary results of the magnetic interaction force.
carrying out similar magnetically saturated statuses for the
Model Types
objects. Therefore, we can draw a conclusion that the
Force Types/N Open Method Yoke Method
performance of the magnetic excitation provided by the open
Fx 0.01 0.02
magnetization method for detecting defects is similar to that
Fy 45.30 360.01
supplied by the traditional yoke one. Fz 0.0 0.0
MFL sensors accomplish their defect scanning for the Ftotal 45.30 360.01
tested objects by dynamic contact and sliding friction.
Magnetic interaction force between MFL sensors and tested
seven times stronger than that caused by the open one, espe- by the broken discontinuities of wire ropes were obtained as
cially for the component of Fy and Ftotal. Hence, a conclusion well as the curve of their peak-to-peak value, as demonstrated
can be drawn that the open magnetization technique can in Figure 7.
sense the need to detach the sensor from the tested object The radial thickness and inner diameter of the ring-shaped
more easily, and therefore causes less wear and damage magnet (made of NdFeB) are 10 mm and 80 mm, respectively,
compared with the yoke technique. Consequently, the open while the magnet length changes from 50 mm to 350 mm in
magnetization technique is more suitable for portable detec- Figure 7a. Similarly, the axial length and inner diameter (ID)
tions of hoist wire rope and has a much longer service life. of the ring-shaped magnet are 300 mm and 80 mm, respec-
The detailed distributions of the magnetic interaction forces tively, while the magnet thickness changes from 10 mm to
to the wire ropes caused by the both magnetizers can be seen 100 mm in Figure 7b. Finally, the conclusion drawn from the
in Figure 6. Figures 7a and 7b is that the bigger axial length and radial
thickness sizes the ring-shaped magnet have, the stronger the
Design of Open Magnetization MFL Sensor for Wire Rope MFL signals produced from wire rope discontnuities would be
Regarding the primary design of the open magnetization MFL when the axial length and radial thickness of the ring-shaped
sensor mentioned above, much attention should be focused magnet are respectively less than 300 mm and 70 mm. Factored
on the ring-shaped permanent magnet magnetizer. Similar to with the low cost in practice application as described previously,
the ring-shaped coil, the key elements of the ring-shaped the middle part of the whole ring-shaped permanent magnet is
permanent magnet sensors are the axial length and the radial creatively replaced by a ring-shaped ferromagnetic material,
thickness. During the simulations, to keep enough assembly while the two sides of the ferrous ring remain magnets. There-
space for the magnetic sensing units, the distance between the fore, Figures 7c and 7d were gained, which indicate that the
surface of the tested wire ropes and the inner center of the MFL signals decrease with the increasing of axial length of the
ring-shaped magnet always remained at 20 mm. The picking ferromagnetic ring with a turning point of 80 mm, and the
up route of magnetic field value (axial component of By and MFL signal is the strongest when radial thick of the ferromag-
radial component of Bz) was set to be 20 mm in axial length netic ring is 15 mm. In fact, permanent magnet ring was just
and 1 mm in radial lift-off. Thereafter, by changing relevant defined as 15 mm according to practice experience at that time.
sizes of permanent magnet and picking up the magnetic fields Indeed, it has also been confirmed that the MFL is the strongest
via the specified route, the MFL signal waveforms produced when the radial thick of the ferromagnetic ring is the same as the
Force type/N
Fx Fy Fz Ftotal
Open method
Model type
Yoke method
Figure 6. Detailed distributions of the magnetic interaction forces simulated by the open method and the yoke method.
10
–0.1 0
–15 –10 –5 0 5 10 15 10 20 30 40 50 60 70 80 90 100
(b) Distance (mm) Magnet length (mm)
5 3.65
Magnetic flux density (T × 10–3)
10
Signal magnitude (T × 10–3)
20 3.6
4 30
40 3.55
50
3 60
70
3.5
80
90
3.45
2 100
3.4
1 3.35
3.3
0
3.25
–0.1 3.2
–15 –10 –5 0 5 10 15 10 20 30 40 50 60 70 80 90 100
(c) Distance (mm) Magnet length (mm)
3.5 3.4
Magnetic flux density (T × 10–3)
5
Signal magnitude (T × 10–3)
3 10 3.3
15
20
2.5 25 3.2
30
2 3.1
1.5 3
1 2.9
0.5 2.8
0 2.7
–0.5
–15 –10 –5 0 5 10 15 5 10 15 20 25 30
(d) Distance (mm) Magnet length (mm)
Figure 7. The magnetic flux leakage signals of a broken-wire discontinuity with the changing of ring-shaped open magnetization MFL sensor
sizes: (a) the MFL signals of a broken-wire discontinuity with the changing of axial length of ring-shaped magnet; (b) the MFL signals of a
broken-wire discontinuity with the changing of radial thick of ring-shaped magnet; (c) the MFL signals of a broken-wire discontinuity with the
changing of axial length of the ferromagnetic ring between two magnet rings; (d) the MFL signals of a broken-wire discontinuity with the
changing of radial thick of the ferromagnetic ring between two magnet rings.
permanent magnet ring by additional simulations. As a result, at one side of the ferromagnetic ring larger than 80 mm. So,
and combined with practice engineering application, the the MFL signals may be bigger than 70 mm, and a turning
ferromagnetic ring is designed to be 80 mm in axial length point is therefore formed.
and 15 mm in radial thick, and the inner diameter is at least Based on the simulation and size optimization described,
70 mm to meet the testing requirement for various detected the open magnetization MFL sensor for wire ropes is
objects with different sizes. designed, as displayed in Figure 8, as simply composed of two
As for the turning point at 80 mm, it may be caused by the parts: a ring-shaped magnet and its unattached ring-shaped
redistribution of the magnetic circuit. Specifically, when the shoe, including magnetic sensing units. The size specifications
axial length of the ferromagnetic ring is less than 70 mm, the of ring-shaped shoes can be immediately met by changing the
magnetic field is mainly produced by the magnetic circuit internal diameters, and one ring-shaped sensor can easily
formed by both the magnet ring and the ferromagnetic ring, accomplish all of the detections for different sized objects just
and the magnetic circuit may only be formed by a magnet ring by replacing the relevant size specifications of ring-shoes.
Specifically, the middle length of the ring-magnet in its axial
Ring-shaped magnet
orientation is designed to be replaced by a ferromagnetic ring
(with ferrous part so that the unattached ring-shaped shoes could easily be fixed
in the middle) inside the inner ring and the whole cost could be reduced.
Ring-shaped shoe Because of this, the hoist wire ropes are fixed by carrying
(magnetic sensing units)
cages at both sides and have no head and tail, and the
designed open magnetizing sensor is easily designed into two
half structures in practice, which merely have the configura-
tion sizes of 120 mm (length) × 100 mm (diameter) and just
weigh about 1.5 kg, which is a small volume and weight.
As indicated in Figure 9, the open magnetization MFL
sensor was tested for the detection capability of a manmade
broken-wire discontinuity in a wire rope (F 32 mm) and the
Figure 8. Open magnetization magnetic flux leakage sensor for steel
magnetic force interaction with the tested wire rope. During
wire rope testing.
the course of experimental testing for detection capability,
Amplifier
(b)
Wire
rope
Filter and A/D
converter
Test signal
Open sensor
for wire pipe
(c)
(a)
Figure 9. Experimental results of the discontinuity detection capability and magnetic interaction forces: (a) testing results of open sensor; (b)
open sensor with 69N magnetic forces; and (c) yoke sensor with 360 N magnetic forces.