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| TCK Could help our
customers to meet the value: |
1.Important wire rope will always be under a controlled and safe testing condition in operation process, which will avoid the rope failure accidents fundamentally and ensure the safety of production.
2.Combining the production process and inspection process into one, which will reduce one process, increase effective operation time and enhance the productivity.
3.Reducing the idling energy consumption of equipment specifically for testing wire rope, and effect of energy saving is obvious.
4.Making the service life of wire rope more effective and proper, saving wire rope replacing time and reduce the cost of wire rope.
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Consumer Assessment |
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Economic Analysis of Applying TCK Wire Rope Online Real-time Automatic |
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Inspection System from Fengfeng Group
Assessment for Applying TCK Steel Cord Conveyor Belt Online Real-time Automatic Inspection System from Chengzhuang Mine, Jincheng Anthracite Mining Group |
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Assessment for TCK Product from the Testing Center of Panggang Group Company Ltd. |
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Assessment for TCK Product from Zhaojiazhai Mine, Zhengzhou Mining Industry Group Company Ltd. |
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Assessment for TCK Product from Professor Tao, Wuhan University of Technology |
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Assessment for TCK Product from Wajinwan Coal Company, Datong Mine |
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Assessment for TCK Product from Xunzhuang Mine, Shanghai Datun Energy Company |
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Assessment for TCK Product from Banji Mine,SDIC XINJI |
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Assessment for TCK Product from Lead-Zinc Mine, Jiangsu Yinmao Controlling Group Company Ltd.,Nanjing |
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Assessment for TCK Product from Junde Mine,Hegang Mining Group |
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Assessment for TCK Product from the Second Mine, Jinchuan Group Ltd. |
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Assessment for TCK Product from Huaxia International Power Supply Company, Xiamen, Fujian |
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Assessment for TCK Product from Changde Special Equipment Inspection and Testing Institute, Hunan |
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Assessment for TCK Product from Jiangzhuang Mine, Zaozhuang Mining Croup,Shandong |
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| Application of TCK Monitoring System at Chengzhuang Mine of Jincheng Anthracite Mining Group
Solved the problem of supervision and management on steel cord conveyor belt Small input and huge return |
Chengzhuang Mine of Jincheng Anthracite Mining Group invested 0.8 million RMB to install Steel Cord Conveyor Belt Online Realtime Inspection System on their No. 1011 conveyor belt which did not only provide Hi-tech safeguard for conveyor belt operation, but also created considerable economic benefits for the enterprise. Every year this system creates obvious benefits of 35.09 million RMB and is also able to do inspection while the belt is running which saves the energy consumption of idle running for manual inspection. Only for this part, the system saved 0.432 million kw/h and effect of energy saving and consumption reducing is outstanding. Meanwhile this system is able to do early diagnosis, early repair and early prevention on conveyor belt breakdown; therefore it extends the service life of the belt, and lowers the maintenance cost significantly.
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Fengfeng Group equipped TCK inspection system Sovled three major problems of Hidden Hazards, Waste, and inefficiency on hoisting wire ropesGain 44 million US dollars of economic benefits
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In order to eliminate safety hazards of hoisting wire ropes, Fengfeng Group invested 1.68 million RMB to equip TCK Weak Magnetic Inspection system for automatically monitoring main hoisting wire ropes of Jiulong Mine, Xuecun Mine, and Dashucun Mine. It did not only eliminate the wire rope operation hazards of the Group, but also created considerable economic benefits.
After Jiulong Mine, Xuecun Mine, and Dashucun Mine equipped TCK Wire Rope Online Automatic Inspection System, every year three mines saved inspection time for 1320 hours, increased production capacity 5.6% averagely. Only for this point, they increased the volume of production for 28.8 tons every year and benefits of 288 million RMB annually. Additionally they saved 0.726 million Kw/H for 1.96 million RMB. Also saved 1/3 cost of rope replacing for 2 million RMB. The ROI rate is reaching 1:180 which really achieved the purpose of small input and huge return.
Using safe Hi-Tech technology to solve operation hazards and eliminate major causes of danger is not only the input, but also huge outcomes: it does not only ensure safety, but also increase benefits of enterprise. The project of wire rope online automatic inspection approved by State Admission of Work Safety provides an example for mining, ports, metallurgy and other industries.
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Wire Rope Online Real-time
Automatic Inspection System |
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| Real-time monitoring the safety status of wire rope Reliably preventing wire rope broken accidents Scientifically reducing the costs of wire rope use Effectively improving wire rope operation efficiency |
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Portable Wire Rope Testers |
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| Quantitatively inspecting wire rope flaws such as broken wires, abrasion, corrosion, and fatigue;Accurately evaluating wire rope residual bearing capacity, safety coefficient and service life. |
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Broken Cord Position Detector |
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| Accurate positioning Easy operation Convenience |
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Elevator Wire Rope Tester |
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| Able to inspect multi-rope at same time |
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| Three Innovations & Two Breakthroughs |
TCK non-destructive inspection technology is an important innovative achievement in the field of wire rope inspection, based on successful discovery on the changes and movement rules of Space Magnetic Field Vector Status. This leading weak magnetic flaws detection technology focuses on 3 innovations and 2 breakthroughs:
1.Establish new theory of "Spatial Magnetic Field Vector Resultant".
2.Discover new method of "Weak Magnetism Inspection".
3.Invent the new technology of "Dou's Element.
Thanks to the 3 innovations, TCK successfully solved the two difficult problems that have puzzled entire world for over a century in non-destructive detecting field:
1.Quantitative detection on various wire rope defects.
2.Online inspection on "fatigue" inside wire rope. |
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| Creative Leading Technology from China |
| Taking the wire rope safety bearing capacity inspection principle as inspection standard, TCK Weak Magnetic Flaw Detector can quantitative detect percentage loss of effective metallic bearing cross-sectional area caused by wire rope's internal or external breakages, abrasion, corrosion and fatigue and other flaws and can correctly evaluate the residual bearing capacity and service life of the inspected wire rope. Its inspection result provides scientific references for safe use and reasonable displacing of wire rope in accordance with the requirements of standards and specifications concerned. TCK Weak Magnetic Flaw Detector is a hi-tech guarantee of effectively preventing accident of breakage wire, properly reducing use cost of wire rope and scientifically enhancing service efficiency of wire rope. |
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| First-class corporate establishes standards |
| The innovative TCK technology provides reliable technical foundation for making the standards of wire rope inspection. TCK takes an active part in drafting China's Coal Industry Professional Standard (MT/T970-2005): Wire Rope Non-destructive Quantitative in-service Inspection Methods and Assessment Rules, which was issued by the National Development and Reform Commission of China on January 17, 2006 and is to be carried out on July 1, 2006.This is not only China's first wire rope inspection standard, but also the world's first standard with assessment rules. The base of this standard is TCK weak magnetic inspection technology; therefore, the technical grade of it is much higher than wire rope inspection standard issued by countries such as USA and France. The implementation of this standard is very significant in that it will radically change the traditional wire rope inspection methods and the improper practice base of periodical rope replacement, thus ensuring the safety of wire rope operation. |
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| The significant breakthrough of TCK Weak
Magnetic Inspection Technology |
For a long time, the scientists in different countries still could not achieve the goal for accurate quantitative inspection of wire rope. Though Strong Magnetic Inspection Technology is developed years ago, but Strong Magnetic Inspection Technology is hard to be accepted by customers due to its serious technical limits, such as cumbersome weight, poor anti-interference, inaccurate test result and complicated operation.
TCK Weak Magnetic Inspection Technology first time accomplished the essential leap from "qualitative inspection" to "quantitative inspection", and the product is rather small and light. So, TCK product has been rapidly accepted by customers at home and abroad once it had been released to market. |
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| Video: Weak Magnetic Inspection Technology developed by TCK makes
China the leader in ferromagnetic material testing field of the world proudly. |
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Hidden dangers is the source of all evil
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Wire rope, as the blind point of safety management, is always concerned during every hoisting. Once wire breakage occurs, the result will be extremely serious.Visual inspection can only find external flaws of wire rope, while invisible internal flaws, such as wire breakage, corrosion, and especially fatigue, are usually more dangerous. As the proverb says, a small leak will sink a great ship.Periodical replacement is still not quite reliable, and causes long-time waste of wire rope. Furthermore, many accidents occur just before wire rope replacement.
TCK weak magnetic inspection can eliminate accidents caused by hidden danger, reduce wire rope cost, and improve productivity. |
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| Five problems in the use of wire rope |
1、Unsafely: Wire breakage accidents caused by strength loss are always existing in the use of wire ropes. According to survey conducted by USA authority organization, 12% in-service wire ropes in 8,000 wire rope laboratories and application sites are in an extremely dangerous situation.
2、Diseconomy: Regular replacement of wire ropes causes huge waste. The statistics from USA indicates that 70% of those compulsively replaced wire ropes have just a little or little strength loss.
3、Inefficiency: Traditional visual inspection method costs long time and labor, and is inefficient.
4、Unreliable: Manual inspection is not reliable and many hidden dangers can not be detected.
5、Catastrophic Consequences: Serious wire breakage accident inevitably caused serious damage. Every year wire rope failure accident always happens in different industries all over the world such as, mining, ports, steel mills, petroleum, ropeway, elevator, hoisting, and transportation. Those accidents cause huge property loss and a heavy toll of lives.
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