Three major technical standards and implementation points for wire rope rust and wear detection

Release time:

2025-03-19

In the investigation of special equipment safety accidents, structural failures caused by latent damage to wire ropes have been a long-standing problem. Industry statistics show that more than 60% of accidents involving hoisting equipment are related to abnormal wire rope conditions. Traditional management methods rely on visual inspection and regular replacement, making it difficult to effectively identify internal corrosion and microscopic damage.

I. Risks Posed by Latent Damage

Concealed Nature of Internal Corrosion
Internal wire breakage in steel wire ropes is often accompanied bya "lantern-shaped" damage pattern, and the missed detection rate of conventional visual inspection exceeds 70%. An analysis of equipment accidents at a certain metal mine shows that the surface integrity of the broken wire rope exceeded 90%, but the effective load-bearing cross-sectional area had been lost by nearly 40%.
Abrupt Characteristics of Wear Development
Frictional wear exhibits a non-linear development pattern: when the diameter reduction reaches the nominal valueof 10%, the breaking strength may suddenly decrease by 30%-50%. Traditional detection methods usually can only detect diameter changes of more than 7%, missing the maintenance window.
Stress Concentration Conduction Effect
Single-point corrosion can increase local stress by3-5 times, triggering a chain reaction of wire breakage in the surrounding area. Conventional detection methods cannot accurately locate stress concentration areas.

II. Technical Requirements of Regulations and Standards

Upgraded Detection Standards
TSG Q7015-2023 clearly stipulates that wire ropes of hoisting equipment must undergo special inspections monthly, and traceable records must be kept.
Improved Accuracy Indicators
GB/T 34129-2023 requires: diameter measurement error ≤ 0.5%, broken wire identification accuracy ≥ 95%.
International Standard Constraints
ISO 4309:2020 emphasizes that internal corrosion and structural deformation parameters must be detected.

Traditional detection methods have gradually failed to meet the requirements of current standards in terms of data record integrity and measurement accuracy.

III. Technical Implementation Path of Intelligent Detection

Current detection equipment addresses industry challenges through technological innovation:

Three-Dimensional Sensing Technology
Using a multi-probe annular array design to construct a three-dimensional model of the wire rope, it can identifychanges in cross-sectional area at the 0.3mm² level, significantly improving the detection capability of internal defects.
Environmental Compensation System
Built-in vibration suppression and temperature compensation modules ensure that the diameter measurement accuracy remains stable within±0.1mm, meeting the special equipment inspection procedures.
Intelligent Early Warning Mechanism
Based on the damage development model, it calculates the degradation trend and generates maintenance suggestions in advance90 days in advance, supporting mobile-end data viewing and early warning reception.