wire-rope-tester-steel-cable-tester-wire-testing

Introduction of wire rope inspection market

Wed, 26 Dec 2012 07:59:29 +0100

As the manufacturer, we believe our wire rope testers could bring new businesses and create new values for your organization. With TCK wire rope testers, your clients will be able to enhance the safety of in-use wire ropes, increase production efficiency and reduce production costs.

As a “high risk” component of important hoisting and conveying equipments, wire rope has always been regarded as the “lifeline” in many industries. However, due to the lack of scientific and reliable inspection instruments, the safety status of in-use wire ropes is a “blind spot” in the operation of hoisting and conveying equipments.

Visual inspection and/or periodical rope replacement have been used to ensure wire rope safety. However, visual inspection can only find flaws on rope surface, but cannot detect internal flaws such as broken wires, corrosion, abrasion and fatigue. As for periodical rope replacement, it cannot assure the safety of in-use wire ropes, while resulting in the waste of at least 1/3 of wire ropes which leads to an increase of production cost.

Each year numerous accidents caused by wire rope failures happen worldwide in such industries as Mining, Ropeway, Power Plant, Elevator, Steel Mill, Shipbuilding, Cable-stayed Bridge, Ports, and Offshore Oil Fields. The loss of human life and damage to properties are shocking.

Introduction to TCK Cableway Wire Rope Online Automatic Inspection System

Wed, 26 Dec 2012 07:54:27 +0100

As a high-risk and key component of cableway equipment, wire rope is regarded as the “lifeline” for the cableway transportation. However, for a long time the rope failure accidents always lurk during the operation of wire ropes due to the lack of scientific and reliable inspection instrumentation. Management departments mostly adopt the methods of visual inspection and periodic replacement of wire ropes to ensure the safety of in-service wire ropes

However Visual inspection only detects external flaws, but cannot detect “major hidden dangers” such as internal broken wires, abrasion, corrosion, fatigue and so on.

Periodic replacement of wire ropes results in huge waste which cannot radically prevent wire rope failure accidents.

Traditional wire rope inspection technology cannot accurately detect the flaws of wire ropes due to its various limitations such as low sensitivity, low repetition rate, influence by speed, “zero drift” and big weight. Therefore the safety of in-service wire ropes has always been the “blind spot” in cableway safety management.

TCK weak magnetism inspection technology successfully solves the difficult problems in the safety inspection of cableway wire rope and provides cableway management departments with reliable method to monitor the safety status of wire ropes, avoid rope failure accidents, scientifically reduce the cost of wire rope replacement and enhance the service efficiency of wire ropes.

To further satisfy the demand of cableway users, TCK has developed Cableway Wire Rope Online Real-time Automatic Inspection System based on the successful development of TCK Portable Wire Rope Testers. Compare to portable wire rope tester, the new system is more advanced in performance and more intelligent in testing process.

TCK Cableway Wire Rope Online Real-time Automatic Inspection System has high detectability on all kinds of Localized Flaws (LF) including broken wire, abrasion, corrosion, fatigue and etc, and also has accurate resolution in the Loss of Metallic Cross-sectional Area (LMA). It can accurately perform quantitative and positioning inspection on all kinds of flaw and also provide reliable inspection reference for evaluating the residual bearing capacity, safety coefficient and service life of the wire rope.

At present, TCK Wire Rope Online Real-time Automatic Inspection System has been widely used to inspect the important wire ropes in the industries of mining, ports, petroleum, steel mills and others. And it’s playing very important role in eliminating wire rope failure accidents radically.

Key words: Wire rope inspection, wire rope test, wire rope defect, wire rope safety, wire rope；wire rope NDT; Conveyor belt inspection; Conveyor belt NDT ；Conveyor belt testing；steel cable inspection/testing; steel cable NDT, steel wire inspection/testing

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Key Features of TCK-BX Portable Wire Rope Testers

Mon, 17 Dec 2012 07:55:10 +0100

1. High inspecting precision, sensitivity and accuracy：the sensitivity of TCK Dou Sensors is 70,000 -250,000 times higher than traditional sensors; with high differentiation rate, the Dou sensor is able to inspect quantitatively all types of wire rope defects;

2. Reliable performance: quantitative uncertainty for measuring the percentage loss of effective bearing metallic cross-sectional area (LMA) and other flaws such as broken wires, corrosion and abrasion (LF) ＜ 0. 5％;

3. High level integration: all function modules are integrated, including system self-diagnosis module, digital automatic calibration module, “Eagle Eye” module, S/N quality module, signal fidelity module, and anti-interference module;

4. Fast data processing capability: by analyzing the original data extracted by TCK testers from the wire rope, TCK patented software is capable of evaluting the working condition of the rope in use. It will not only display the testing result and print out the test report in real time, but also exchange data between the tester and a PC at fast speed;

5. Small size and light weight: TCK-BX standard rope testers weigh less than 2 KG or 1/6~1/20 lighter than traditional wire rope NDT testing equipments. Therefore, it is very easy to operate;

6. Wide applicability: applicable to wire rope inspections under complex working conditions and not be affected by the inspectors’ experience or skills, rope speed, noise, water spraying, warped wires, oil dirt and other factors;

7. Accurate inspection results: capable of quantitatively measuring the percentage loss of effective bearing metallic cross-sectional area (LMA), caused by internal and/or external broken wires, abrasion, corrosion, fatigue and other defects and thereby evaluate the residual bearing capacity and service life of the inspected wire rope.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Functions of TCK-BX Portable Wire Rope Testers

Mon, 17 Dec 2012 07:50:59 +0100

1. Quantitatively detecting both external and internal flaws such as broken wires, abrasion, corrosion, fatigue, and other defects; and correctly evaluating the inspected wire rope’s residual bearing capacity, safety coefficient and service life;

2. Real time Sound/Light alarm function during the inspection process;

3. Online automatic calibrating technique to ensure the accuracy of inspection results;

4. Self-diagnosis function to ensure the system operate reliably;

5. Quantitatively calculate broken wires in one lay length or 6D/30D length and rope diameter reduction;

6. Integrated design of testing instrument and meters, with no need for external power supply and cable connection;

7. With a working space of 20-30 mm between the testing heads and the wire rope surface and the opposite motion mode of the guide wheels and wire rope, TCK portable rope testers have exceptional passing capability, which is not affected by broken wires, rope deformation, oil sludge, dirt and other factors, and capable of inspecting under any working conditions;

8. During inspection, the tester’s inner bush will not rub against the wire rope directly and intensively; and it is designed for permanent use, with no need to replace or maintain.

9. Trigger type self-unlocking device, which quickly unlock the tester from the rope in emergency situation to ensure the safety of the inspectors and the equipment;

10. Easy for operation because of simple instrument keyboard setting, rolling linear logic interface switch, indicative man-machine conversation, and embedded intelligent program operation;

11. As soon as an inspection is completed, the inspectors can check the inspection data, flaw curves, analysis report, and numerical inspection result on the tester’s LCD screen; if the tester is connected to a printer, a formal test report can be printed out;

12. High performance rechargeable Lithium Polymer battery unit;

13. Testing head employs high strength, insulated anti-corrosive material to prevent electricity leakage, short circuit, and electric shock by lightning;

14. Quantitative inspection methods and evaluation rules meet the requirements prescribed in MT/T970-2005 Non-destructive and Quantitative Inspection Methods and Evaluation Rules for Wire Rope and other industries’ standards and requirements;

15. The instrument is CE certified and has no electromagnetic pollution; it does not interfere with the normal operation of other electronic and communication equipments in the work locale;

16. Water, dust, oil and moisture proof.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Function Units of TCK-BX Portable Wire Rope Testers

Mon, 17 Dec 2012 07:45:38 +0100

1) DC electromagnetic coils;

2) TCK system self-diagnosis module --- automatically check the system status before inspection;

3) TCK digital module --- AD/DA signal conversion;

4) TCK “Eagle Eye” detecting module --- calibrating and signal extracting;

5) TCK S/N quality module --- signal quality fidelity;

6) TCK 128 x 128 LCD Display --- real-time display of testing results;

7) Embedded 32-bit industrial CPU --- support 32M data recording, storing, retrieving, processing, converting and displaying;

8) Large capacity program storage system;

9) Large capacity data storage system --- maintaining testing data for 10 years without power supply;

10) Imbedded hardware real-time clock.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Technical Specifications of TCK-BX Portable Wire Rope Testers

Mon, 17 Dec 2012 07:38:08 +0100

1. Inspection technology: weak magnetism inspection technology; Inspection Sensitivity: Amax = 5 V/G; Sensitivity modulation value: A = 2.6 V/G;

2. Operating magnetic field strength: < 20 MT;

3. Test rope diameter range: 1-200 mm (as defined by specific models);

4. Testing interval differentiation rate: 0.002 m;

5. Rope speed: Vmax = 30 m/sec; controlled rope speed range: V = 0.2-13 m/sec; safety testing rope speed: V < 2 m/sec; inspecting resolution not affected by rope speed;

6. Inspection accuracy: Pmax < 0.05%;

7. Uncertainty for measuring the percentage loss of effective metallic bearing cross-sectional area (LMA): P < 1%;

8. Inspected rope length collating error: C ＜ 10 mm/100 m;

9. Slight defects: detecting capability > 90%

Major defects: detecting capability > 99%

10. Total weight for the testing head unit: standard model ≤ 2KG; advanced model ≤3.6KG

11. Dimension (length, width, and height) for the testing head unit: standard model = 268 x 195 x 172 mm; advanced model = 420x160 x275 mm

12. Wide-space inspection and the gap between the sensor and the surface of the rope: 20-30 mm

13. Temperature range: -30℃ ～ +55℃; No temperature drift

14. Work environment humidity: ≤ 95% RH.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Introduction of TCK-BX Portable Wire Rope Testers

Mon, 17 Dec 2012 07:30:54 +0100

TCK-BX portable wire rope testers adopt patented Weak Magnetism inspection technology and have been recognized as the solution to the problems of “Hidden Dangers, Waste, and Low efficiency” of wire rope use. This equipment is able to correctly evaluate the residual carrying capacity and service life of in-service wire ropes by quantitatively detecting both internal and external flaws such as broken wires, corrosion, abrasion and fatigue. With this technical breakthrough in NDT technology, it is possible for the first time in the world to scientifically evaluate in-service wire rope’s residual bearing capacity, safety coefficient, and service life.

TCK portable rope testers weigh only 2 KG, about 1/6~1/25 of the weight of conventional NDT testers. The sensitivity of TCK Dou sensors could reach 5 V/G and the accuracy for evaluating the percentage loss of effective bearing metallic cross-sectional area is above 99.5%. It is also easy to operate, with unique auto-unlocking device and friendly interface designs.

When an inspection is completed, TCK rope testers are able to display on the LCD screen testing data, flaw graph, data table, and test report. After connecting to a computer and printer, a formal test report could be printed, which provides scientific reference for users to use wire ropes more safely and replace wire rope more appropriately.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

TCK--The Most Outstanding Enterprise With Customer Added Value Service

Mon, 17 Dec 2012 07:25:11 +0100

l TCK invent the leading edge weak magnetic inspection technology

l TCK Weak Magnetic Technology was listed in 2007 State Torch Project and 2008 China Production Safety Technology Research Project

l TCK is the only high-tech enterprise qualified as post-doctoral workstation in wire rope inspection field.

l The China standard MT/T970-2006 “On-line Nondestructive Quantitative Inspection Method and Determination Rule for Wire Rope/Cable” in coal mine field is based on TCK weak magnetic inspection technology.

l TCK has passed ISO9001 quality management system certificate, Certificate of Type Approval of China Classification Society and National Mining Machinery Certificate

l TCK has passed Safety certificate of approval for mining products and Explosion- proof Certificate

l TCK has passed USA FCC certificate, EU CE certificate and Canadian IC certificate.

l TCK inspection products have captured over 80% Chinese market share and have more than 1500 important clients in the world; some famous companies, like OTIS, ABB, SIEMAG, POSCO, FOERSTER have become TCK stable customers.

l TCK has solved the worldwide difficult problem in the wire rope inspection field, and won the “Labor Medal” issued by local government.

l After 5-year development, the enterprise value of TCK has grew 200 times and also becomes the No. 1 brand in wire rope and steel cord conveyor belt inspection field of the world.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

TCK Wire Rope Inspection Technology Co., Ltd.

Mon, 17 Dec 2012 07:01:48 +0100

TCK Wire Rope Inspection Technology Co., Ltd is a High–Tech Company in researching, manufacturing, spreading and serving non-destructive inspection instruments for ferromagnetic materials. We have the most advanced “weak magnetic” core technology and all the intellectual property of this independently-developed high-tech innovation.

TCK Wire Rope non-destructive and quantitative inspection system is a successful application of the weak magnetic inspection technology in the area of strip ferromagnetic materials. Since we have discovered and mastered the change and movement rules of the space magnetic field vector around the wire rope, and have achieved three innovations in setting new principles of the Vectorial Resultant of the Spatial Magnetic Field, finding the new method of weak magnetic inspection, and inventing a highly sensitive sensor, we have successfully solved two difficult problems which have puzzled the entire world for over a century in quantitative detection of the rope flaws and fatigue.

At present, TCK has developed a series of products, including TCK portable inspection models, TCK wired/wireless On-line Automatic Inspection System, TCK Wire Rope Non-destructive Flaw Detector for Elevator, and TCK Steel-cord Conveyor Belt On-line Inspection System, to meet the demands of different customers in mining, harbor, ropeway, petroleum, electric power, hoisting, elevator, cable stayed bridge, missilery base and other wire rope related area.

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm

Main Customers of TCK Wire Rope Inspection Technology Co., Ltd.

Thu, 29 Nov 2012 06:51:04 +0100

TCK Major International Customers
1.U.S. OTIS 2.German FOERSTER 3.Japanese Maitsubishi Heavy Industries 4.Korean KOSHA 5.Korean POSCO 6.Indonesia PT KAMBA SAMBILAN 7.U.S. Phillips Petroleum Company
8.Indonesia PT Netway Indonesia 9.The Port of Amsterdam, Netherlands 10.National Iranian Oil Company 11.MoroccoBCI Maroc 12.Hutchison Whampoa Ltd of Hong Kong 13.The Port of Kaohsiung, Taiwan
Major Domestic Mining Customers
1.Datong Coal Mine Group 2.Shanxi Coking Coal Group Company 3.Luan Mining Group
4.Jincheng Coal Mine Group 5.Shenhua Group Corporation Ltd 6.Fengfeng Coal Mine Group
7.Fenxi Mining Group Corporation Ltd of Shanxi province 8.Beipiao Coal Mines Co., Ltd.
9.Tiefa Coal Mines Group of Liaoning province
10.Fushun Coal Mine Group Corporation Ltd of Liaoning province 11.Pingzhuang Coal Mines (Group) Co. Ltd 12.Tangshan Steel Group Corporation Ltd of Hebei province
13.Zaozhuang Mining Group 14.Zhaojin Mining Co., Ltd
15.Pingdingshan Coal Mines Group 16.Huating Coal Mines Group
17.Qinghai Coal Mines Group 18.Tonghua Mining Group 19.Lianzhao Mining Group
20.Huaxing Nonferrous Metals (Group) Corporation 21.Shanghai Electric High voltage Industry Co., Ltd
22.Shandong Gold group……
Major Domestic Customers in the Petroleum and Ports industries
1.Customers in Petroleum Industry
– Daqing Oilfield LIaohe Oilfield Jilin Oilfield
– Yumen Oilfield Tuha Oilfield Changqing Oilfield
– Talimu Oilfield Jidong Oilfield Great Wall Drilling Company
– Andong Petro Group China National Petroleum Corp. China National Offshore Oil Corporation
2.Customers in Ports Industry
– Shanghai International Port (Group) Co., Ltd. Shanghai Zhenhua Port Machinery Co,Ltd.
– GUANGZHOU PORT GROUP Dalian Port Group Shenzhen Chiwan Sembawang Engineering Co., Ltd.
– Tianjin Port (Group) Co., Ltd. Shenzhen Seastar Port Develop Co., Ltd Wuhan Port Affair Group Co.
– Taicang International Container Terminal Co., Ltd China Ocean Shipping Company (COSCO)
Major Customers in the Steel, State NDT Services and Other Industries
1.Customers in Steel Mills Industry
– China Shougang Group Shanghai Baoshan Steel Group
– Anshan Steel Group Wuhan Steel Group
– Jianlong Iron & Steel Co., Ltd Lingyuan Iron & Steel Co.,Ltd
– AnYang Iron& Steel Inc. Taiyuan Iron& Steel (Group) Co., Ltd
– Tangshan Iron & Steel Co., Ltd Baotou Iron& Steel (Group) Co., Ltd
2.Customers in Special Inspection Industry
– Beijing Bureau of Quality and Technical Supervision
– Shenzhen Institute of Special Equipment Inspection and Test
– Wuxi Special Equipment Inspection and Research Institute
– Liaoning Safety Science Research institute

Max Wang

TCK Wire Rope Inspection Technology Co., Ltd.

Tel：86-379-6511-2821

Email: maxwang@tck-cn.com

http://www.tck-cn.com/en/index.htm