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Experimental and numerical Experimental and numerical characterisation of characterisation of
ferromagnetic ropes and ferromagnetic ropes and non-destructive non-destructive testing devicestesting devices
Aldo Canova (1), Fabio Degasperi (2), Francesco Ficili (4), Michele Forzan (3), Bruno Vusini (1)
(1) Dipartimento di Ingegneria Elettrica - Politecnico di Torino (Italy)(2) Laboratorio Tecnologico Impianti a Fune (Latif) – Ravina di Trento,
Trento (Italy)(3) Dipartimento di Ingegneria Elettrica - Università di Padova (Italy)
(4) AMC Instruments – Spin off del Politecnico di Torino (Italy)
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
ContentsContents
• Magneto-Inductive (M-I) inspection: LF and
LMA signals
• Magnetic rope characterisation
• Design of Magneto-Inductive devices
• Experimental results
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
M-I inspection: the working principleM-I inspection: the working principle• A strong magnet is placed as close as possible to the rope,
thus obtaining the rope saturation.
• Rope defects cause a flux change (value and shape) that is revealed by means of a flux sensor
N S
N S
Reduction in the main flux
Local modification of the flux path
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Type of sensors in use:
• coils (are sensitive to the flux changes)
• hall-effect (are sensitive to the flux density)
M-I inspection: the working principle
There are two (main) kinds of M-I instruments, depending on the way the flux is measured:
• LF (Localized Fault): the leakage flux is measured
• LMA (Loss of Metallic cross-section Area): the main flux is measured
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
LF InstrumentsLF Instruments
This is the most used technique to identify damages in a metallic rope
DamageMagnetic Flux distorsion
Very sensitive to the external broken wires Reduced sensitivity to the internal defects No quantitative information about damages
Working principle:• Rope defects cause a flaw of the magnetic flux• The flaw has two component: axial and radial
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
LMA instruments
Working principle:• Rope defects cause a
variation of the rope area• The main magnetic flux is
proportional to the rope area• The rope area is obtained by
measuring the main magnetic flux
Independent form position of broken wires (external or internal) Quantitative information Suitable to detect gradual changes of the rope section due to corrosion Reduced sensitivity for broken wires very closed (narrow gap) Strong influence of external leakage fluxes (end effects)
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
LF and LMA traces
Rope Profile
LMA
LF
Device length higher than width of loss metallic area
Narrow gaps
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
•The M-I test is significantly influenced by the magnetic behaviour of the metallic rope
•The magnetic behaviour of a metallic rope depends from its magnetic characteristic (B-H plane) and its hysteresis loops
Magnetic rope characterisation
Soft magnetic material
Hard (or semi hard) magnetic material
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
•The measurement of the B-H characteristic of a magnetic material has been obtained as interpolation of the vertexes of several symmetric hysteresis cycles. The measurement has been done establishing a magnetic field H, with a controlled magnitude and direction, in the region where the magnetic material is placed.
Magnetic rope characterisation
•The wire rod has been bended and welded at the edges, the total length of the ring was 60 cm. •The toroidal inductor has been built by winding 2050 turns around a rubber tube.
•The magnetizing inductor is made by 4 separate coils, 1000 turns, 16 cm length each with a diameter of 6 cm (ratio between the length and the diameter is around 10). •The field magnitude in the centre of the system is about equal to 6250 turns/meter, when the inductor is empty.
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Magnetic rope characterisation
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0.0E+0 5.0E+3 1.0E+4 1.5E+4 2.0E+4 2.5E+4 3.0E+4 3.5E+4
H0 [A/m]
B [T
]
0
50
100
150
200
250
300
350
0 5000 10000 15000 20000 25000 30000 35000 40000
H0 [A/m]
m R
B-H characteristicRelative permeability of the sample wire rod
Rope NameRedaelli158 mm2
Redaelli473 mm2
Ercole[Reverse Lay]
497 mm2
Ercole[Reverse Lay]
1374 mm2
Chiusa1861 mm2
Rope Typestranded, core yarn,
Seale type
stranded, core yarn,, Warrington-Seale
type
metallic core, reverse lay, external stranded
metallic core, reverse lay, external stranded
rifle, double external layer with Z-formed
wires
Diameter [mm] 20 34 31 52 53
Construction 6(9+9+1)+PPC6(12+6/6+1)
+PPC12(6+1)+24
+18+ 12+6+112(6+1)+30
+24+18+12+6+1
1+6+12+18+24+30+32
+37
Number of wires 114 186 145 175 160
Lay Z/Z Z/Z - Z/S Z
Metallic cross section [mm2]
158 473 497 1374.3 1861
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Magnetic rope characterisation
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2
0.0E+0 5.0E+3 1.0E+4 1.5E+4 2.0E+4 2.5E+4 3.0E+4 3.5E+4
MAGNETIC FIELD H0 [A/m]
Indu
ctio
n [e
quiv
alen
t] B
' [T
]
Radaelli 158 Radaelli 473 Reverse Lay 497 Reverse Lay 1374 Closed Rope 1861
Iron
•The magnetic behaviour of the metallic rope is far from a “soft material”
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Magnetic rope characterisation•For the LF signal a low permeability is required
0
50
100
150
200
250
300
350
400
0.0E+00 5.0E+03 1.0E+04 1.5E+04 2.0E+04 2.5E+04 3.0E+04 3.5E+04 4.0E+04 4.5E+04 5.0E+04
Magnetic Field H0 [A/m]
Re
lati
ve
pe
rme
ab
ility
mrel redaelli S = 1861 mm2
mrel Fune Redaelli S = 473 mm2
mrel Fune Ercole S = 1374.3 mm2
mrel Fune Ercole S = 497 mm2
mrel Fune Redaelli S = 158 mm2
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Design of Magneto-Inductive devices•The performance evaluation of magnetic inductive detectors can be performed by studies of magnetic fields with numerical methods:
•Three dimensional domains•Non linear magnetic materials
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Experimental results
-100 -80 -60 -40 -20 0 20 40 60 80 100-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
B [
T]
Axial Position [mm]
Simulation Experimental
Magnetic flux density trend inside the detector versus axial position without rope for the Device1
-100 -80 -60 -40 -20 0 20 40 60 80 100-0.20
-0.15
-0.10
-0.05
0.00
0.05
0.10
0.15
0.20
B [
T]
Axial Position [mm]
Simulation Experimental
Magnetic flux density trend inside the detector versus axial position without rope for the Device 2
•The main performance indicator is the magnetic saturation of the rope which depends from the magnetic flux density at “no magnetic load” conditions (device without rope)•Without rope is possible to provide a comparison between experimental and simulated magnetic field
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Experimental results•The magnetic behaviour under working conditions (with rope) can be simulated but is difficult to make experimental measurements.•To provide the measurements, a proper rope prototype consisting on two pieces facing each other has been realized, the faced surfaces have been suitable worked to make them smooth as possible. •The two lengths of rope are placed inside the detector and separated by a small air gap. The air gap allows the insertion of a probe for static magnetic field measurement.•The axial component of such magnetic flux density inside the air gap is closed to those reached inside the rope under test.
-100 -80 -60 -40 -20 0 20 40 60 80 100-1.5
-1.0
-0.5
0.0
0.5
1.0
1.5
2.0
B [
T]
Axial Position [mm]
Simulation without gap Simulation with gap of 1.5 (mm) Experimental with gap of 1.5 (mm)
OIPEEC Confference 2009 and 3rd International Stuttgart Ropedays18th - 20th March 2009 - Stuttgart, Germany
Conclusions•The goodness of the M-I technique is linked to the magnetic behaviour of the rope under test•In the design of a M-I device is important to take into account the magnetic characteristic of the rope which is usually an unknown information•In the present paper the experimental characterization of a set of ropes with different size is presented and it puts in evidence that the rope material is far from “soft magnetic material” and requires high magnetic field for reaching the desired saturation level•The numerical field analysis of a M-I device is possible and a good agreement can be obtained between experimental and simulation results•The virtual prototyping allows a fast and reliable optimized design of M-I devices
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