Search Results (23)

The magnetic flux leakage (MFL) method is widely acknowledged as a highly effective non-destructive evaluation (NDE) technique for detecting local damage in ferromagnetic structures such as steel wire ropes. In this study, a multi-channel MFL sensor module was developed, incorporating a purpose-designed Hall sensor array and magnetic yokes specifically shaped for steel cables. To validate the proposed damage detection method, artificial damages of varying degrees were inflicted on wire rope specimens through experimental testing. The MFL sensor module facilitated the scanning of the damaged specimens and measurement of the corresponding MFL signals. In order to improve the signal-to-noise ratio, a comprehensive set of signal processing steps, including channel equalization and normalization, was implemented. Subsequently, the detected MFL distribution surrounding wire rope defects was transformed into MFL images. These images were then analyzed and processed utilizing an object detection method, specifically employing the YOLOv9 network, which enables accurate identification and localization of defects. Furthermore, a quantitative defect detection method based on image size was introduced, which is effective for quantifying defects using the dimensions of the anchor frame. The experimental results demonstrated the effectiveness of the proposed approach in detecting and quantifying defects in steel cables, which combines deep learning-based analysis of MFL images with the non-destructive inspection of steel cables. Full article

This research presents the development and management principles of mobile resonant electrical systems designed for high-voltage generation, intended for non-destructive diagnostics of insulation in high-power electrical equipment. The core of the system is a series inductive–capacitive (LC) circuit characterized by a high quality (Q) factor and operating at high frequencies, typically in the range of 40–50 kHz or higher. Practical implementations of the LC circuit with Q-factors exceeding 200 have been achieved using advanced materials and configurations. Specifically, ceramic capacitors with a capacitance of approximately 3.5 nF and Q-factors over 1000, in conjunction with custom-made coils possessing Q-factors above 280, have been employed. These coils are constructed using multi-core, insulated, and twisted copper wires of the Litzendraht type to minimize losses at high frequencies. Voltage amplification within the system is effectively controlled by adjusting the current frequency, thereby maximizing voltage across the load without increasing the system’s size or complexity. This frequency-tuning mechanism enables significant reductions in the weight and dimensional characteristics of the electrical system, facilitating the development of compact, mobile installations. These systems are particularly suitable for on-site testing and diagnostics of high-voltage insulation in power cables, large rotating machines such as turbogenerators, and other critical infrastructure components. Beyond insulation diagnostics, the proposed system architecture offers potential for broader applications, including the charging of capacitive energy storage units used in high-voltage pulse systems. Such applications extend to the synthesis of micro- and nanopowders with tailored properties and the electrohydropulse processing of materials and fluids. Overall, this research demonstrates a versatile, efficient, and portable solution for advanced electrical diagnostics and energy applications in the high-voltage domain. Full article

The Co-Cr-Fe-Ni high-entropy alloy (HEA) is particularly suitable for preparing coatings due to its excellent comprehensive properties. In this study, we use the laser cladding method to prepare Co-Cr-Fe-Ni HEA coatings with Co-Cr-Fe-Ni cable-type welding wire (CTWW) as the filling material and investigated the dilution rates of the coatings by experimental studies and first-principles calculations. The dilution rate is reduced to about 50% by changing the wire feeding speed, and a Co-Cr-Fe-Ni HEA coating with near nominal composition was prepared by multi-layer cladding. The HEA coating with near nominal composition is successfully prepared in the fourth layer of cladding. The coating is dense and uniform, with good metallurgical bonding. The mechanical properties of the coating were explored using first-principles calculations. All four coatings exhibit a single face-centered cubic (FCC) phase with good mechanical stability in the ground state. The bulk modulus B, shear modulus G, and Young’s modulus E of the four layers of coatings are gradually decreasing from B = 202 GPa, G = 136 GPa, and E = 334 GPa to B = 239 GPa, G = 154 GPa, and E = 380 GPa. The brittleness of the coating shows a trend of first decreasing and then increasing, and the coating closest to the nominal composition has the highest brittleness. Full article

As automatic test technology advances, the number of programmable instruments in a single test system increases. Traditional wired communication methods have a limited range and involve complex cable layouts. Single-function wireless converters provide a viable alternative, but they have limitations. These include complicated configuration, issues with multi-system collaboration, and data blocking. This paper proposes a wireless ad hoc network platform for multi-bus instruments based on a low-cost ESP-12H WiFi module. The platform supports GPIB, RS232, RS485, and CAN bus interface instrument access. It features easy configuration, ad hoc networking, and self-repairing capabilities. A relay multi-hop network with a tree topology expands capacity and coverage. Additionally, a dynamic window-receiving mode and an improved multi-priority queue ensure data transmission integrity. The experimental results show that the platform’s networking time is less than 10 s, and the coverage range reaches 50 m in complex indoor environments. It also shows good stability when running for a long time. However, due to hardware and software design limitations, the actual upload speeds fall short of the theoretical values. For example, RS232 and RS485 are about 10% slower than the theoretical values, and GPIB is about 80% slower. Further optimization is required in the future. Full article

The combination of the dark fiber in existing Optical Fiber Composite Overhead Ground Wire (OPGW) with Distributed Optical Fiber Sensing (DOFS) technology can be used to enable online monitoring and provide early warnings of anomalies in high-voltage transmission lines. Accurate mapping of the optical cable length to the geographic coordinates of actual towers is a key factor in achieving this goal. This paper discusses the principle of using a DOFS system for transmission line tower positioning and presents four available positioning features. To overcome the limitations of single physical parameter positioning, this paper presents a self-developed hybrid DOFS that simultaneously captures Rayleigh backscattering and Brillouin scattering signals. Several physical parameters, including temperature, strain, and vibration, are acquired synchronously. Through hybrid multi-parameter analysis, the rapid and accurate positioning of OPGW line towers is achieved. Experimental results have shown that the proposed method, based on the hybrid DOFS system, can locate up to 82 towers, while the traditional method could only identify 12. The hybrid system was able to complete 80% of the tension towers in 40 h. This paper presents a novel multi-parameter localization method that has the potential to significantly improve the efficiency and reliability of grid operation and maintenance. Full article

The planning of multi-branch cable harness layouts holds significant practical importance in aircraft industrial contexts, yet it has received limited attention in prior research. This study aims to address the matter concerning the significance of managing multiple constraints and preventing loops. It formulates the problem as an optimization problem in 3D free-form space and resolves it using an extended A* path planning approach in combination with the ant colony optimization algorithm. Initially, a feasible search space for wiring is established through the repair and simplification of the input CAD model. Subsequently, the topology of a multi-branched wiring harness is identified, taking into account industrial requirements related to cable physics, turning, support, bundling, and electromagnetic compatibility constraints. Specifically, the disassembly or merging of branches and loops is employed to avoid wire loops. Ultimately, we propose an A*–ant colony optimization algorithm (A*-ACO) with an enhanced heuristic function for neighboring points, incorporating a concentration increment model. Experimental tests illustrate the effectiveness of this approach in minimizing wire loops and reducing the total cable layout cost, considering factors such as length, bundling, and turning costs. It results in a reduction of 67.0%, 68.5%, and 51.1% compared to A*, ACO, and manual wiring methods, respectively. Full article

The main cable is the primary load-bearing component of a long-span multi-tower suspension bridge. The interaction between a dead load, vehicle load, wind load, and the corrosion environment leads the main cable wire to exhibit tribo-corrosion-fatigue behaviors. This behavior causes wire wear and deterioration, as well as a reduction in the effective cross-sectional area. This leads to the gradual deterioration of the wire’s load-bearing strength and seriously affects the load-bearing safety of the main cable. In order to ensure the safety of suspension bridges, it is critical to investigate the gradual deterioration behavior of the main cable wire’s load-bearing strength. A wire tribo-corrosion-fatigue test rig was established to test the wire under different friction pairs (saddle groove or parallel wires). The cross-sectional failure area of the wire with different pairs was obtained by super-depth electron microscopy and calculation. The damage degree evolution model and the deterioration model of the wire load-bearing strength were established by combining the theory of damage mechanics and the finite element method. The results show that, as contact and fatigue loads increase, so does the cross-sectional failure area of the fatigue steel wire. The fatigue wire’s damage degree has a good quadratic function relationship with fatigue cycles. The damage degree of the wire increases and the load-bearing strength decreases with increasing contact load and fatigue load. The load-bearing strength of the wire changes little at the beginning and decreases with increasing fatigue cycles. The results have fundamental significance for the life prediction of the main cable wires of suspension bridges. Full article

Compared with traditional cables, superconducting multi-stage cables have the natural advantages of greater transmission power and less energy loss, which have gradually attracted attention. However, conventional multi-stage cables are based on low temperature superconducting (LTS) technology and there is considerable scope for improvement in their performance. In this paper, a novel structure of the multi-stage high temperature superconducting (HTS) twisted cable prepared by the soldered-stacked-square (3S) wire is proposed. The AC loss characteristics of the twisted cable are deeply studied by experiments and simulation. Through the experiment, the influence of the voltage-leads on the AC loss measurement accuracy is eliminated, and frequency dependent is shown in the AC loss of the twisted cable. Besides, the simulated value of AC loss is consistent with the experimental value, which verifies the accuracy of the simulation. The AC loss of twisted cable is only 20% of that of the thin strip model, which reveals its outstanding advantages in AC loss. Full article

An umbilical cable is a compactly integrated cable consisting of electrical power cables, communication (electric signal) cables, and chemical transposition tubes. An umbilical cable is widely used in developing oil and gas resources of deep and ultra-deep water. With the increment of the length and the functional integration of umbilical cables, the crosstalk becomes a crucial issue in the cable design, and needs to be evaluated carefully before the fabrication and installation. Moreover, the twisted structure of communication cable cores has incurred extra difficulties to the crosstalk calculation. Nevertheless, it is not an easy task to model the complex twisted structure in existing models and methods of the crosstalk computation. In this regard, this paper proposes a numerical methodology for the crosstalk calculation considering the multi-conductor twisted structure of the cable cores. In the methodology, the four-wire twisted structure is modelled as a cascade of uniform multiconductor transmission line (MTL) sections, each wire section covering a length of 1/4 pitch, with abrupt interchanges of wire positions at the ends. The chain-parameter equation is introduced to describe the voltage and current transfer relationship in each MTL section. To obtain the numerical solutions of the twisted cable system, the port constraint equations and the permutation matrices are also required and developed. The per-unit-length parameters of the umbilical cable system are computed by numerical methods. The feasibility to engineering applications and accuracy of the proposed methodology is validated by experimental results, and the crosstalk characteristics of communication cables in a typical umbilical cable under different operating conditions are investigated. Full article

Due to the exponential growth in offshore renewable energies and structures such as floating offshore wind turbines and wave power converters, the research and engineering in this field is experiencing exceptional development. This emergence of offshore renewable energy requires power cables which are usually made up of copper to transport this energy ashore. These power cables are critical structures that must withstand harsh environmental conditions, handling, and shipping, at high seas which can cause copper wires to deform well above the limit of proportionality and consequently break. Copper, being an excellent electric conductor, has, however, very weak mechanical properties. If plasticity propagates inside copper not only will the mechanical properties be affected, but the electrical properties are also disrupted. Constantly monitoring such large-scale structures can be carried out by providing continuous strain using fiber-optic sensors (FOSs). The embedding of optical fibers within the cables (not within the phase) is practiced. Nevertheless, these optical fibers are first introduced into a cylinder of larger diameter than the optical fiber before this same fiber is embedded within the insulator surrounding the phases. Therefore, this type of embedding can in no way give a precise idea of the true deformation of the copper wires inside the phase. In this article, a set of numerical simulations are carried-out on a single phase (we are not yet working on the whole cable) with the aim of conceptualizing the placement of FOSs that will monitor strain and temperature within the conductor. It is well known that copper wire must never exceed temperatures above 90 °C, as this will result in shutdown of the whole system and therefore result in heavy maintenance, which would be a real catastrophe, economically speaking. This research explores the option of embedding sensors in several areas of the phase and how this can enable obtaining strain values that are representative of what really is happening in the conductor. It is, therefore, the primary objective of the current preliminary model to try to prove that the principle of embedding sensors in between copper wires can be envisaged, in particular to obtain an accurate idea about strain tensor of helical ones (multi-parameter strain sensing). The challenge is to ensure that they are not plastically deformed and hence able to transport electricity without exceeding or even becoming closer to 90 °C (fear of shutdown). The research solely focuses on mechanical aspects of the sensors. There are certainly some others, pertaining to sensors physics, instrumentation, and engineering, that are of prime importance, too. The upstream strategy of this research is to come up with a general concept that can be refined later by including, step by step, all the aspects listed above. Full article

With the development of smart grids, the application of localized relay protection devices has greatly reduced the distance between the secondary equipment and the primary equipment. The secondary equipment will be in a more complex electromagnetic environment during the operation of the GIS disconnector. The present study takes the multi-path electromagnetic disturbance on the secondary cable caused by the disconnector switching operation of the domestic 1000 kV ultra-high voltage GIS test circuit as the research background, solves the field-line coupling problem based on the finite integral technique, and combines the multi-conductor transmission line theory to solve the radiation disturbance and obtains its influencing factors. The results demonstrate that the radiated disturbance accounted for 16% of the overall electromagnetic disturbance when both ends of the shielding layer are grounded. The use of grounding at both ends of the shielding layer, reducing the height of the secondary cable wiring, avoiding the parallel arrangement of the secondary cables and the GIS pipe mother, and installing a low-pass filter, have different levels of suppression effects on electromagnetic disturbances. The research results will guide the reasonable arrangement of secondary cables in GIS substations to some extent and have reference significance for the protection of secondary equipment. Full article

The traditional cable-based geophone network is an inefficient way of seismic data transmission owing to the related cost and weight. The future of oil and gas exploration technology demands large-scale seismic acquisition, versatility, flexibility, scalability, and automation. On the one hand, a typical seismic survey can pile up a massive amount of raw seismic data per day. On the other hand, the need for wireless seismic data transmission remains immense. Moving from pre-wired to wireless geophones faces major challenges given the enormous amount of data that needs to be transmitted from geophones to the on-site data collection center. The most important factor that has been ignored in the previous studies for the realization of wireless seismic data transmission is wireless channel effects. While transmitting the seismic data wirelessly, impairments like interference, multi-path fading, and channel noise need to be considered. Therefore, in this work, a novel amalgamation of blind channel identification and deep neural networks is proposed. As a geophone already is responsible for transmitting a tremendous amount of data under tight timing constraints, the proposed setup eschews sending any additional training signals for the purpose of mitigating the channel effects. Note that the deep neural network is trained only on synthetic seismic data without the need to use real data in the training process. Experiments show that the proposed method gives promising results when applied to the real/field data set. Full article

Industrialization has led to a huge demand for a network control system to monitor and control multi-loop processes with high effectiveness. Due to these advancements, new industrial wireless sensor network (IWSN) standards such as ZigBee, WirelessHART, ISA 100.11a wireless, and Wireless network for Industrial Automation-Process Automation (WIA-PA) have begun to emerge based on their wired conventional structure with additional developments. This advancement improved flexibility, scalability, needed fewer cables, reduced the network installation and commissioning time, increased productivity, and reduced maintenance costs compared to wired networks. On the other hand, using IWSNs for process control comes with the critical challenge of handling stochastic network delays, packet drop, and external noises which are capable of degrading the controller performance. Thus, this paper presents a detailed study focusing only on the adoption of WirelessHART in simulations and real-time applications for industrial process monitoring and control with its crucial challenges and design requirements. Full article

Shape memory alloy (SMA) actuators have recently demonstrated their potential for various applications in fields such as robotics, medicine, aerospace, and automotive. Its features, such as low weight and high force, simplicity, noiseless operation, and low cost compared with other conventional actuator, are only a few advantages of this actuator, which is receiving increasing interest among researchers. However, the use of these actuators is still limited by some of their characteristics: high position error in the cooling stage when the actuator works at frequencies that exceed the necessary cooling time and high electrical energy consumption. Different actuator configurations can help minimize these disadvantages through modifying the length, the number of cables, or the sheath used in the actuator, which modify the characteristics of the complete system. In this work, we developed different configurations of SMA actuators and tested their performance in terms of efficiency and the position error in the cooling stage. The findings demonstrate that over-dimensioned actuators are more energetically efficient and present a faster initial form recovery. The multi-wires actuator configuration produce a better response in terms of position but are less energy efficient. These conclusions allow for the selection of the most appropriate configuration based on the requirements of each particular application. Full article

Alternative wireless data communication systems are a necessity in industries that operate in harsh environments such as the oil and gas industry. Ultrasonic guided wave propagation through solid metallic structures, such as metal barriers, rods, and multiwire cables, have been proposed for data transmission purposes. In this context, multiwire cables have been explored as a communication media for the transmission of encoded ultrasonic guided waves. This work presents the proprietary hardware design and implementation of an automatic data transmission system based on the propagation of ultrasonic guided waves using as communication channels a high-temperature and corrosion-resistant oil industry multiwire cable. A dedicated communication protocol has been implemented at physical and data link layers, which involved pulse position modulation (PPM), digital signal processing (DSP), and an integrity validation byte. The data transmission system was composed of an ultrasonic guided waves PPM encoded data transmitter, a 1K22 MP-35N multiwire cable, a hardware preamplifier, a data acquisition module, a real-time (RT) DSP LabVIEW (National Instruments, Austin, TX) based demodulator, and a human-machine interface (HMI) running on a personal computer. To evaluate the communication system, the transmitter generated 60 kHz PPM energy packets containing three different bytes and their corresponding integrity validation bytes. Experimental tests were conducted in the laboratory using 1 and 10 m length cables. Although a dispersive solid elastic media was used as a communication channel, results showed that digital data transmission rates, up to 470 bps, were effectively validated. Full article