Wire Rope Defect Recognition Method Based on MFL Signal Analysis and 1D-CNNs

• Published in: Sensors (Basel, Switzerland) Switzerland), 2023-03, Vol.23 (7), p.3366
• Main Authors: Liu, Shiwei, Chen, Muchao
• Format: Article
• Language: English
• Subjects: Accuracy; Algorithms; Classification; convolutional neural network (CNN); Data analysis; Deep learning; defect detection; Defects; feature extraction; Inspection; Machine learning; Magnetic flux; Magnetic flux leakage testing; Methods; Neural networks; Noise; Nondestructive testing; Recognition; Sensors; Signal analysis; Signal processing; Stress concentration; Wavelet transforms; Wire; Wire rope
• ISSN: 1424-8220; 1424-8220
• DOI: 10.3390/s23073366

The quantitative defect detection of wire rope is crucial to guarantee safety in various application scenes, and sophisticated inspection conditions usually lead to the accurate testing of difficulties and challenges. Thus, a magnetic flux leakage (MFL) signal analysis and convolutional neural networks (CNNs)-based wire rope defect recognition method was proposed to solve this challenge. Typical wire rope defect inspection data obtained from one-dimensional (1D) MFL testing were first analyzed both in time and frequency domains. After the signal denoising through a new combination of Haar wavelet transform and differentiated operation and signal preprocessing by normalization, ten main features were used in the datasets, and then the principles of the proposed MFL and 1D-CNNs-based wire rope defect classifications were presented. Finally, the performance of the novel method was evaluated and compared with six machine learning methods and related algorithms, which demonstrated that the proposed method featured the highest testing accuracy (>98%) and was valid and feasible for the quantitative and accurate detection of broken wire defects. Additionally, the considerable application potential as well as the limitations of the proposed methods, and future work, were discussed.