Steel wire ropes are used for transporting personnel and materials in coal mines. Its quality directly affects the safety of mining operation and hence, it is important to accurately identify the defects. Since the electromagnetic detection methods are affected by large amounts of noise, more precise strategies are required. This paper proposes a noise reduction method based on K-singular value decomposition (K-SVD) optimized double-tree complex wavelet transform (DTCWT). Firstly, the discrete coefficients of the evaluation index of different decomposition levels in DTCWT are calculated to obtain the optimal decomposition levels. Afterwards, K-SVD is used to update the sparse dictionary. The decomposed high-frequency modes were optimized for noise reduction. Finally, DTCWT was used to reconstruct the damage detection signal from the wire rope, after noise reduction. The experimental results show that the signal to noise ratio obtained using the proposed method is 30% higher than the other algorithms. The smoothing coefficient obtained is lower than 0.01, whereas the correlation coefficient is found to be more than 0.95, which indicates that the proposed algorithm can effectively reduce the noise in the detection signal and significantly retain its original characteristics, thereby improving the safety of the wire rope.

As a common load-bearing component, mining wire rope produces different types of damage during a long period of operation, especially in the case of damage inside the wire rope, which cannot be identified by the naked eye, and it is difficult to accurately detect such damage using the present technology. In this study we designed a non-destructive testing device based on leakage magnetism, which can effectively detect the internal defects of wire rope damage, and carried out simulation analysis to lay a theoretical foundation for the subsequent experiments. To address the noise reduction problem in the design process, a variational mode decomposition–adaptive wavelet thresholding noise reduction method is proposed, which can improve the signal-to-noise ratio and also calculate the wavelet energy entropy in the reconstructed signal to construct multi-dimensional feature vectors. For the quantitative identification of system damage, a particle swarm optimization–support vector machine algorithm is proposed. Moreover, based on the signal following the noise reduction step, seven different feature vectors, namely, the waveform area, peak value, peak-valley value, wavelet energy entropy classification, and identification of internal and external damage defects, have been determined. The results show that the device can be used to effectively identify internal damage defects. In addition, the comparative analysis showed that the algorithm can reduce the system noise and effectively identify internal and external damage defects with a certain superiority.

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.

In order to solve the problem of great difficulty in detecting the internal damage of wire rope, this paper proposes a method to improve the VGG model to identify the internal damage of wire rope. The short-time Fourier transform method is used to transform the wire rope damage signal into a time-frequency spectrogram as the model input, and then the traditional VGG model is improved from three aspects: firstly, the attention mechanism module is introduced to increase the effective feature weights, which effectively improves the recognition accuracy; and then, the batch normalization layer is added to carry out a uniform normalization of the data, so as to make the model easier to converge. At the same time, the pooling layer and the fully connected layer are improved to solve the redundancy problem of the traditional VGG network model, which makes the model structure more lightweight, greatly saves the computational cost, shortens the training time, and finally adopts the joint-sample uniformly distributed cross-entropy as the loss function to solve the overfitting problem and further improve the recognition rate. The experimental results show that the improved VGG model has an identification accuracy of up to 98.84% for the internal damage spectrogram of the wire rope, which shows a good identification ability. Not only that, but the model is also superior, with less time-consuming training and stronger generalization ability.

Mining wire rope, a frequently used load-bearing element, suffers various forms of damage over extended periods of operation. Damage occurring within the wire rope, which is not visible to the naked eye and is difficult to detect accurately with current technology, is of particular concern. Consequently, the identification of internal damage assumes paramount importance in ensuring mine safety. This study proposes a wire rope internal damage noise reduction and identification method, first of all, through a three-dimensional magnetic dipole model to achieve the detection and analysis of the internal damage of the wire rope. Simultaneously, a sensor system capable of accurately detecting the internal damage of wire rope is developed and validated through experimentation. A novel approach is proposed to address the noise reduction issue in the design process. This approach utilizes a particle swarm optimization variational modal decomposition method to enhance the signal-to-noise ratio. Additionally, a dual-attention mode, which combines channel attention and spatial attention, is integrated into the CNN-GRU network model. This network model is specifically designed for the detection of internal damage in steel wire ropes. The proposed method successfully achieves quantitative identification of internal damage in steel wire ropes. The experimental findings demonstrate that this approach is capable of efficiently detecting internal damage in wire rope and possesses the capacity to quantitatively identify such damage, enabling adaptive identification of wire rope.