Wire rope is a key component of traction and lifting equipment with high consumption and high risk. Its scientific and efficient use plays an important role in production safety, energy conservation and consumption reduction, reducing operating costs, improving equipment utilization, and increasing enterprise output value.
Routine manual inspection and maintenance are certainly important, but in the era of intelligence, machine monitoring is far more sustainable, reliable, and predictable than manual inspection.
Recently, one coal mine introduced multiple TST real-time online intelligent flaw detection systems for wire ropes to conduct all day safety monitoring of the four-rope hoist wire ropes, replacing manual inspection with machine intelligent inspection, and elevating wire rope safety monitoring to a higher level.
For a long time, the inspection of the mine's hoisting system has mainly relied on manual labor, which is not only labor-intensive and inefficient, but also unable to grasp the operating status of the first rope in real time. For this reason, the mine introduced TST four-rope hoist wire rope intelligent flaw detection system.
“FAST”---this system can achieve 24 hour/day, 365 day/year full life cycle supervision by real-time online monitoring and warning and it is easy to operate and use, which saves much maintenance time.
“Precise”---while replacing manual inspection, the system can detect, analyze and store the internal and external status of the hoist wire rope in real time during operation, issues early warning information when abnormal conditions are detected, and generates an inspection report immediately, replacing the data report previously obtained through manual measurement.
“Accurate”---can detect various damages such as broken wires, wear, corrosion, fatigue, etc. The innerside and outside of the wire ropes, and also correctly evaluate the remaining load-bearing capacity and service life of the tested wire rope, and provide users with a scientific basis for safe use and reasonable updates that meet standards and specifications.
1. It can save the workload of at least 2 inspection workers per year, and greatly reduce the downtime for rope inspection, which can reach 100+ hours in total.
2. Save 600,000 kW·h of startup energy consumption specifically for rope inspection, and save 30000USD in electricity.
3. Save 800,000 kw-hours of inspection energy per year and reduce carbon dioxide emissions by 800,000 kilograms.
4. Extend the use time of wire ropes: under the standard operation , it will extend at least service life of wire ropes by one year, and reduce the cost of ropes by one third. The annual cost of ropes can be reduced from USD130000 to less than USD85000.
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