What does SMRT mean?
SXRT stands for:
- Stuttgart Magnetic Rope Testing
- Stuttgart High-Resolution Rope Testing
- Stuttgart Diameter Rope Testing
- Stuttgart Visual Rope Testing
Magneto inductive rope testing in general
Why magnetic inductive rope testing?
Wire ropes in operation have a limited service life. Safe operation is therefore only possible if the ropes are inspected regularly and discard maturity, i.e. the rope condition at which the rope must be replaced, is detected safely and in good time before a dangerous operating condition occurs. Usually ropes indicate their incipient destruction after a certain running time through abrasion and wire breaks. Wire ropes distribute their stress over up to four hundred individual wires and are usually still safe to operate even if some of the wires have broken. The discard wire breakage numbers are specified in the respective standards according to the rope application. Only the outer wires of a wire rope can be inspected visually. The inner wires remain hidden from visual inspection. The illustration shows the cross-section of a fully locked suspension rope. Visually, only the outer Z-position can be assessed.
Principle of magnetic inductive rope testing
For safety-critical applications, it is therefore necessary to measure the outer and inner condition of the wire rope. For this purpose, the magnetic induction method became established very early on because of its practicality and reliability. In particular, operators of cableways and haulage ropes in mining use the magnetic induction testing of wire ropes.
The history of magnetic induction rope testing goes back to the beginning of the 20th century. In 1906, the South Africans McCann and Colson described the magnetic testing of wire ropes for the first time. In 1931, research work in the field of magnetic induction rope testing was started by Woernle at the Institute for Materials Handling Technology at the University of Stuttgart (IFT). Until the seventies, the magnetisation of the rope was carried out by means of coils with direct current flowing through them. In an effort to further simplify magnetic-inductive rope testing, a testing device with permanent magnets was developed in the mid-1970s by the Institute for Conveying Technology at the University of Stuttgart. By using high-performance magnetic materials, the weight and dimensions of the magnetisation unit could be reduced considerably.
What types of ropes can be tested magneto-inductively?
In principle, magnetic induction rope testing can be used to test all types of steel wire ropes.
Can the entire cross-section of a rope be tested?
Yes, EN 12927:2019 requires a magnetization by the test equipment in the core of the rope of at least 1.9 Tesla.
Can individual wire breaks be detected during magnetic induction rope testing?
Yes, wire breaks mean a change in the metallic cross-section of the rope. Even the smallest changes are reliably detected.
Rope tester SMRT
Who developed the SMRT devices?
More than 80 years of research and experience of the Institute for Materials Handling and Logistics IFT of the University of Stuttgart have gone into the development and continuous improvement of the SMRT devices.
What connects the IFT of the University of Stuttgart with MESOMATIC GmbH & Co. KG?
MESOMATIC is a development partner of the Institute for Mechanical Handling and Logistics IFT of the University of Stuttgart, produces the SMRT devices and is responsible for worldwide sales and service.
What are the outstanding features of SMRT devices?
In addition to reliable operation, special emphasis is placed on easy handling under the sometimes difficult conditions of practical use.
The SMRT devices are designed for one-man operation, act independently of weather, surface and light conditions and are not affected by snow, ice, dirt or poor lighting conditions. The design of the magnets and the measuring coils ensures that even the smallest and most varied faults on and in the rope can be reliably detected, displayed and thus interpreted.
• 24/7 use
• Harsh environmental conditions
• Precise analysis
• Permanent surveillance
• and much more.
For which rope diameters are SMRT devices suitable?
The SMRT units are available in 4 standard sizes
• SMRT 25 for rope diameter 5..28 mm
• SMRT 40 for rope diameter 14..45 mm
• SMRT 60 for rope diameter 35..62 mm
• SMRT 70 for rope diameter 35..70 mm
• SMRT 100 for rope diameter 70..100 mm
Rope diameters up to 140 mm can be tested with special designs
What scope of delivery is required for a measurement?
The following minimum equipment is required for a magnetic induction rope test:
• 1 rope tester SMRT (24 / 40 / 60 / 70 / 100)
• 1 measuring box
• 1 pair of measuring coils (size depending on rope diameter)
• 2 pairs of guide blocks (size depending on rope diameter)
• 1 measuring wheel
• 1 laptop for operation, display and evaluation
Can I upgrade my existing equipment with WLAN connection and Li-ion batteries?
es, there is the SMRT 1.8 upgrade kit that allows you to upgrade your existing equipment to the most modern level. You can use all the advantages of the new SMRT 1.8 measuring control with our upgrade package and continue to use all your hardware (magnet, measuring coils, guide jaws) unchanged.
In addition to the possibility of wireless measurement (WLAN), the new generation offers forward and backward movement during measurement and the use of the new SMAQS Recorder software. You can find all the advantages for download here.
What means SMRT 1.8?
With the new SMRT 1.8 system, the SMRT series has been brought up to the latest state of the art. In addition to the possibility of wireless measurement (WLAN), the new generation offers forward and backward movement during measurement and the use of the new SMAQS Recorder software. You can find all the advantages for download here.
What are the advantages of the new SMAQSAnalyzer software?
• complete compatibility with old measurement files
• display of the direction reversal and automatic cutting out of the "reverse"
• comparison of multiple measurements and automatic carry forward of already known
• wire breaks
• fully automatic report generation
• use of a template for customer-specific test reports
• automatic data retrieval of a customer/ropedatabase (transfer of customer data, wire
breaks from previous measurements)
• complete measurement data processing and evaluation of all SXRT files
• user-friendly and multifunctional user interface
Can the measuring box only be placed on the magnet?
If space is an issue, the measuring box can also be placed next to the magnet.
Are the SMRT units suitable for mobile or stationary use?
The SMRT units can be used both mobile and stationary.
How to transport the laptop?
The laptop is transported in a sturdy transport case with an integrated charging tray for the batteries of the measuring electronics and space for the measuring electronics and other accessories.
How many batteries for the measuring electronics does the measuring case contain?
The scope of delivery includes 2 batteries (one battery as a spare).
Are separate measurement electronics required for each magnetic tester?
No, one measuring electronics can be used for several magnets.
Dimensions and weights
SMRT 25 in Pelicase
SMRT 40 in Pelicase
SMRT 60 in Zargesbox
SMRT 70 in Zargesbox
How are the rope testers transported?
The rope testers are transported in a sturdy transport case with an adapted inlay together with the measuring coils and guide jaws.
Why is the size of the measuring coils and guide jaws dependent on the rope diameter?
The measuring coils and guiding blocks are interchangeable so that the rope tester can be centered optimally on the rope and the measuring coils can be positioned as close as possible to the rope.
Can I add guiding blocks and measuring coils for further rope diameters at a later date?
Are the rope testers certified?
The rope testers are certified according to EN 12927:2019 by the IFT (Institute of Mechanical Handling and Logistics) of the University of Stuttgart. According to EN 12927:2019, recertification is required every 3 years, which we are happy to perform for you.
What is the IP class of the magnetic head and the measuring PC?
The SMRT 1.8 measuring electronics and the measuring coils as well as the closed measuring case comply with protection class IP 64. The magnetic head can be cleaned with a high-pressure cleaner after dismantling the coils.
Can you also use your own laptop in the PeliCase?
Yes, this is possible in principle, but it is more difficult to answer support requests because we then have no knowledge of the laptop’s condition and system settings.
Is it possible to install the analysis software multiple copieson different computers?
Yes, there are no license costs, because the software may be used on multiple computers.
Is there a possibility to automatically pass over obstacles e.g. rope riders and support shoes of ropeways?
Yes, we offer a pneumatic lifting device for the SMRT 60 and the SMRT 70, which enables manually controlled automatic opening and lifting of the rope tester.
Does the lifting device include the connection (mech. connection) to the trolley of the aerial tramway?
Yes, a so-called drawbar is included in the scope of delivery. However, this is only universal within certain limits. The connection to the drive/ice scraper must always be adjusted on site. This drawbar is a bolted tool in H-shape. Two perforated plates on the sides and a centre section for stiffening. We can gladly provide you with the drawings.
What is the volume of the supplied pressure cylinder for the lifting device?
The compressed air cylinder is a cfk cylinder (composite material) with a volume of 6.8 litres and 300 bar. The big advantage of the cylinder is the significantly lower weight compared to a steel cylinder. The use of cfk cylinders has proven itself for many years.
How many lifts can be made with one compressed air cylinder?
This cannot be said in general terms, depending on the rope diameter (due to the increased magnetic force as there is more metallic cross-section). On average, it can be assumed that 50-60 actuations (1 actuation = 1 x up + 1x down) are possible with one bottle filling.
Is an additional compressed air bottle required?
Depending on the self-sufficiency requirements of the rope test, it may be advantageous to have a second cylinder. However, the cylinders are equipped with a pressure gauge so that the operator can estimate how much compressed air is still available. In addition, the compressed air cylinder can usually be filled in any diving shop or at the fire brigade.
No standard testing device will fit my ropes. Can you supply something adapted?
Come to us with your requirement. We will be very happy to check how we can meet your special requirement.
How is the supply of spare and wear parts ensured?
We usually have all necessary spare and wear parts in stock or can manufacture them at short notice. The University of Stuttgart and MESOMATIC both have a long history, which guarantees continuity and ensures the long-term availability of spare parts.
Can the equipment be demonstrated?
We have the option of doing an online demonstration, or you can come to us at the impressive rope lab at the Institute of Mechanical Handling and Logistics at the University of Stuttgart, or we can come to you and demonstrate the equipment at your facility or your customer’s facility.
Rope testing with SMRT
How is the measurement started?
The measurement is started on the laptop.
How is the rope tester connected to the laptop?
The connection between the laptop and the rope tester is established via WLAN. Alternatively, in poor ambient conditions (e.g. a lot of steel in the surrounding area), a cable connection can also be used.
What is the maximum range of the WLAN connection?
On an open track with a clear view, a range of 80 -100 m is possible.
What happens if the WLAN connection is interrupted during the measurement?
SOnce the measurement is started, a loss of connection will not result in any loss of data. Disconnecting the connection can take a long time without any problems, the measurement data is completely written to the internal SD card. After successful completion of the measurement, the complete measurement data can be loaded from the SD card.
How long does a battery charge of the measuring box last?
At least 8 hours can be measured with one battery charge, even at low temperatures.
In which speed range can be measured?
Measurements with coils can be performed in the velocity range 0.3 to 5 m/s. When using Hall sensors, measurements can be made in a speed range of 0 - 5 m/s.
Is it possible to set the sampling rate in the acquisition software?
The EN 12927 standard states that one measuring point should be recorded for every 1 mm along the length of the rope (example: if the rope is running at 2 m/s, frequency setting to 2000 Hz). With our system, the frequency is adjusted automatically. The measuring wheel serves as a trigger. This means that one measured value per 1 mm is stored. Completely independent of the speed. When the measuring wheel moves 1 mm, a measured value is written.
Is it possible to detect corrosion inside a rope without wires already broken?
Corrosion produces a clear widening of the measurement signal in the MI measurement record. It can therefore be recognised. However, it cannot be said across the board that every signal widening in the MI measurement record is also due to corrosion. This means that a signal widening cannot be equated with internal corrosion. In this case, the corresponding rope zone (in which the signal widening occurred) must be visually inspected. This is the only way to draw concrete conclusions between the MI measurement and corrosion.
I have not done any rope testing before. Can you support me?
Our team will be happy to support you in selecting the appropriate equipment and, of course, also through training in building up your rope testing know-how.
Is training required?
We recommend training to familiarise our customers with the operation of the measuring programmes and the handling of the magnetic head and, if necessary, the lifting device. This can be carried out on your premises or at the IFT of the University of Stuttgart.
One training day is usually sufficient to be able to adequately assess ropes. If the training participants already have previous knowledge in handling magnetic heads, the training can also be carried out online in half a day.
◦ Editing, cutting, appending, ...
◦ Semi-automatic wire break detection
◦ Wire break history - detection of already known wire breaks
◦ Display of test speed and test direction
◦ "Reverse travel" is automatically isolated
◦ Comparison of two measurements in the same editor window
◦ Evaluated measurement can be saved as a locked file
Do you still have questions that we have not been able to answer here?
Click here for the enquiry form