Hall-effect sensors are used for the non-destructive testing of wire ropes owing to their low power consumption and high operation frequency. The high-speed operation of wire ropes causes vibration inclination at different frequencies, which makes it difficult to detect the ropes. Considering that the radial signal in the magnetic flux leakage (MFL) detection method can respond to damages to the maximum extent possible, this study proposes a radial magnetic concentrator suitable for the non-destructive testing of wire ropes based on theoretical analysis and transient magnetic field simulations. The concentrator improves the radial magnetic circuit, polymerizes the leakage of the magnetic field in the detection device, and the leakage of the magnetic field of the defect converges at the sensor position of the circumferential array to improve the signal-to-noise ratio of the Hall-effect sensor. In addition, the MFL field is homogenized through the structure of the magnetic concentrator when the wire rope is tilted, which weakens the influence of the vibration tilt of the wire rope on the test results. Finally, the experiments show that the amplitude of the wire-rope damage signal is effectively improved by using the proposed radial magnetic concentration technology, hence being convenient for defect analyses.
Keywords: finite element analysis; flexible printed circuit; magnetic concentrator bridge; radial magnetic vector; signal characteristic; signal extraction; wire-rope detection.