CN116289275A - Manufacturing method of wire rope prefabricated broken wire rope sample - Google Patents
Manufacturing method of wire rope prefabricated broken wire rope sample Download PDFInfo
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- CN116289275A CN116289275A CN202310114712.5A CN202310114712A CN116289275A CN 116289275 A CN116289275 A CN 116289275A CN 202310114712 A CN202310114712 A CN 202310114712A CN 116289275 A CN116289275 A CN 116289275A
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- wire rope
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/06—Ropes or cables built-up from metal wires, e.g. of section wires around a hemp core
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/10—Rope or cable structures
- D07B2201/1004—General structure or appearance
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/10—Rope or cable structures
- D07B2201/1012—Rope or cable structures characterised by their internal structure
- D07B2201/102—Rope or cable structures characterised by their internal structure including a core
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Investigating Strength Of Materials By Application Of Mechanical Stress (AREA)
Abstract
The invention discloses a manufacturing method of a wire rope prefabricated broken wire rope sample, which comprises the steps of selecting a wire rope structure and specification according to the requirement of the broken wire rope sample; selecting a wire rope sample type, the wire rope sample type comprising: class a, class B, class C; calculating the sum of the cross sectional areas of all steel wires in the steel wire rope; respectively calculating the diameters of steel wires to be replaced in the class A and the class B according to the specified area loss amount, and calculating the diameter of the steel wire to be increased in the class C according to the specified area increase amount; producing steel wires with corresponding diameter specifications for standby; for the class A and class B rope samples, firstly, the replaced steel wire is drawn out from the rope sample, and then the spare steel wire is added; for the C-type rope sample, straightening the steel wire rope along the length direction, disassembling the outer layer strands, adding a spare steel wire to the steel wire rope steel core, and fixing the spare steel wire between the steel core gaps; obtaining a prepared rope sample, and cutting off and removing the replaced or added steel wire according to the specific wire breakage interval requirement; fixing the steel wire at the cut-off position firmly, and marking the defect position.
Description
Technical Field
The invention belongs to the technical field of steel wire rope manufacturing, and particularly relates to a manufacturing method of a prefabricated broken wire rope sample of a steel wire rope.
Background
The steel wire rope is a spiral steel wire bundle which is formed by twisting steel wires with mechanical properties and geometric dimensions meeting the requirements together according to a certain rule. In a materials handling machine, for lifting, pulling, tensioning and carrying. The steel wire rope has high strength, light dead weight and reliable work. If wire breakage occurs in the wire rope during manufacture, transportation, and use, there is a significant risk of safety in the use of the wire rope and in the use of equipment to which the wire rope is attached. Therefore, the research on the breakage of the steel wire rope is very important.
The broken wire is the most common quality defect in the use of the steel wire rope, different standards have differences on the waste judging conditions of the broken wire, and in practice, how to determine the scrapped base point of the steel wire rope becomes a technical key, so that the scrapped base point of the steel wire rope is influenced mainly by the change of the effective metal cross-sectional area, and in practical application, the broken wire or abrasion directly influences the cross-sectional area of the steel wire rope. Therefore, the wire breakage research of the steel wire rope becomes a key technology in the industry, a wire breakage rope sample is required to be prefabricated according to standard requirements in a laboratory, the actual industrial and mining is simulated for detection, and theoretical analysis and actual manufacturing are carried out; therefore, it is necessary to develop a method for manufacturing a prefabricated broken wire rope sample of a steel wire rope so as to provide scientific basis for laboratories.
Disclosure of Invention
Aiming at the problems, the invention makes up the defects of the prior art and provides a manufacturing method of a wire rope prefabricated broken wire rope sample; the method can be used for manufacturing the wire rope sample with the wire breakage defect meeting the standard requirement, and provides the wire rope sample with the standard requirement for a laboratory.
In order to achieve the above purpose, the present invention adopts the following technical scheme.
The invention provides a manufacturing method of a wire rope prefabricated broken wire rope sample, which specifically comprises the following steps:
step 1, selecting a steel wire rope structure and specification according to the requirements of a broken wire rope sample;
step 2, selecting a broken wire rope sample type according to the requirement of the broken wire rope sample, wherein the broken wire rope sample type comprises: class A, class B and class C, wherein class A is a wire rope surface wire breakage sample, class B is a wire rope steel core wire breakage sample, and class C is a wire rope addition wire breakage sample;
step 3, calculating the sum of the cross sectional areas of all steel wires in the steel wire rope, and selecting a broken wire rope type according to the step 2; respectively calculating the diameters of steel wires to be replaced in the class A and the class B according to the specified area loss amount, and calculating the diameter of the steel wire to be increased in the class C according to the specified area increase amount;
step 4, producing steel wires with corresponding diameter specifications for standby according to the steel wire diameter calculated in the step 3;
step 5, according to the calculated diameter in the step 4, for the broken wire rope sample of the class A and the class B, firstly, the replaced steel wire is extracted from the rope sample, and then the spare steel wire is added; for the C-class broken wire rope sample, straightening the steel wire rope along the length direction, disassembling the outer layer strands, adding a spare steel wire to the steel wire rope steel core, and fixing the spare steel wire between the steel core gaps;
step 6, obtaining a prepared rope sample according to the step 5, and cutting off and removing the replaced or added steel wire according to the specific wire breakage interval requirement;
and 7, fixing the steel wire at the cut-off position firmly, preventing loosening, and marking the defect position.
Further, in the step 1, a steel wire rope with a 16×19S-IWRC structure is selected, and the diameter specification of the steel wire rope is 24mm.
Further, in the step 3, the diameter of the steel wire in the outer layer of the outer strand of the steel wire rope which needs to be replaced in the class A is calculated, the diameter of the steel wire in the outer layer of the steel core which needs to be replaced in the class B is calculated, and the diameter of the steel wire which needs to be increased between the gaps of the steel core in the class C is calculated.
Further, in the step 3, the steel wire diameter is calculated reversely from the area by adopting the relationship between the area and the radius of the circle.
Further, in the step 5, the spare wire is added to the steel core of the steel wire rope, and the spare wire is fixed between the gaps of the steel core by adopting glue.
Further, in the step 6, the specific wire breakage distance is 760mm.
The beneficial effects of the invention are as follows: the method for manufacturing the wire rope prefabricated broken rope sample can finish the manufacturing of the wire rope broken rope sample with specific broken wire spacing requirements according to requirements, so that the manufacturing method of the wire rope broken rope sample is more direct and simpler.
Drawings
FIG. 1 is a schematic diagram of the length and position of a broken wire made according to the present invention.
Detailed Description
In order to make the technical problems, technical schemes and beneficial effects solved by the invention more clear, the invention is further described in detail below with reference to the accompanying drawings and the detailed description. It should be understood that the detailed description is presented by way of example only and is not intended to limit the invention.
Example 1
The embodiment of the invention provides a manufacturing method of a wire rope prefabricated broken wire rope sample, which specifically comprises the following steps:
step 1, selecting a steel wire rope structure and specification according to the requirements of a broken wire rope sample;
step 2, selecting a broken wire rope sample type according to the requirement of the broken wire rope sample, wherein the broken wire rope sample type comprises: class A, class B and class C, wherein class A is a wire rope surface wire breakage sample, class B is a wire rope steel core wire breakage sample, and class C is a wire rope addition wire breakage sample;
step 3, calculating the sum of the cross sectional areas of all steel wires in the steel wire rope, and selecting a broken wire rope type according to the step 2; and respectively calculating the diameters of various steel wires to be replaced according to the specified area loss: calculating the diameter of the steel wire in the outer layer of the outer strand of the steel wire rope to be replaced in the A type, and calculating the diameter of the steel wire in the outer layer of the outer strand of the steel core to be replaced in the B type; the wire diameter to be increased is calculated according to the prescribed area increase amount: the C type calculation requires the diameter of the steel wire to be increased between the gaps of the steel core; by adopting the relation between the area and the radius of the circle, the diameter of the steel wire is reversely calculated from the area.
And 4, producing the steel wire with the corresponding diameter specification for standby according to the steel wire diameter calculated in the step 3.
Step 5, according to the calculated diameter in the step 4, for the broken wire rope sample of the class A and the class B, firstly, the replaced steel wire is extracted from the rope sample, and then the spare steel wire is added; and (3) for the C-class broken wire rope sample, straightening the steel wire rope along the length direction, disassembling the outer layer strands, adding the spare steel wire into the steel wire rope steel core, and fixing the spare steel wire between the steel core gaps by adopting glue.
And 6, preparing a rope sample according to the step 5, and cutting off and removing the replaced or added steel wires according to the specific wire breakage interval requirement.
And 7, fixing the steel wire at the cut-off position firmly, preventing loosening, and marking the defect position.
Example 2
The embodiment of the invention provides a manufacturing method of a wire rope prefabricated broken wire rope sample, which specifically comprises the following steps:
step 1, taking a 6X 19S-IWRC structure steel wire rope as an example, wherein the diameter specification of the steel wire rope is 24mm, and respectively manufacturing rope samples of A type, B type and C type broken wire rope samples.
Step 2, selecting a broken wire rope sample type: the A type is a wire rope surface wire breakage rope sample, the B type is a wire rope steel core wire breakage rope sample, and the C type is a wire rope addition wire breakage rope sample;
step 3, calculating the sum of the cross-sectional areas of all steel wires in the steel wire rope to be 282.14mm 2 ；
Step 3.1, the specified area variation is 0.5% of the sum of all the sectional areas of the steel wire ropes, and the loss area of the class A broken rope sample is 1.41mm 2 Calculating the diameter of the outer strand outer layer steel wire to be replaced to be 1.34mm according to the relation between the area and the radius of the circle;
step 3.2, the specified area variation is 0.1% of the sum of all the sectional areas of the steel wire ropes, and the loss area of the class B broken rope sample is 0.282mm 2 Calculating the diameter of the steel core outer strand outer layer steel wire to be replaced to be 0.60mm according to the relation between the area and the radius of the circle;
step 3.3, the prescribed area variation is 0.1% of the sum of all the sectional areas of the steel wire ropes, and the increased area of the C-type broken wire rope sample is 1.41mm 2 The diameter of the steel wire to be added is calculated to be 1.34mm according to the relation between the area and the radius of the circle;
step 4, producing 1 standby steel wire with the diameter of 1.34mm by the class A broken wire rope sample, producing 1 standby steel wire with the diameter of 0.60mm by the class B broken wire rope sample, and producing 1 standby steel wire with the diameter of 1.34mm by the class C broken wire rope sample;
step 5, replacing the steel wire or adding the steel wire;
step 5.1, extracting a steel wire from an outer strand outer layer steel wire of the steel wire rope by the class A broken wire rope sample, and replacing the steel wire with a spare steel wire of 1.34mm;
step 5.2, drawing out a steel wire from the outer layer steel wire of the outer strand of the steel core of the steel wire rope by the B-type broken wire rope sample, and replacing the steel wire with a spare steel wire of 0.60mm;
and 5.3, straightening the steel wire rope along the length direction by using the C-type broken wire rope sample, disassembling the outer layer strands, adding the spare steel wire with the diameter of 1.34mm into the steel wire rope steel core, and fixing the spare steel wire between the steel core gaps by adopting glue.
Step 6, 10 different broken wire lengths are manufactured, and the specific lengths are as follows: 1.5mm, 3mm, 6mm, 12mm, 25mm, 50mm, 100mm, 200mm, 400mm, 800mm; the length of the manufactured steel wire is calculated according to the linear distance of the steel wire rope, the distance between every two broken wires is 760mm, and the position error is less than or equal to 20mm, as shown in figure 1;
step 7, straightening the steel wire rope along the length direction, and fixing the steel wire at the cut-off position firmly to prevent loosening; at the defect, marks are made on the wire rope according to the defect length.
It should be understood that the foregoing detailed description of the present invention is provided for illustration only and is not limited to the technical solutions described in the embodiments of the present invention, and those skilled in the art should understand that the present invention may be modified or substituted for the same technical effects; as long as the use requirement is met, the invention is within the protection scope of the invention.
Claims (6)
1. A manufacturing method of a wire rope prefabricated broken wire rope sample is characterized by comprising the following steps of: the method specifically comprises the following steps:
step 1, selecting a steel wire rope structure and specification according to the requirements of a broken wire rope sample;
step 2, selecting a broken wire rope sample type according to the requirement of the broken wire rope sample, wherein the broken wire rope sample type comprises: class A, class B and class C, wherein class A is a wire rope surface wire breakage sample, class B is a wire rope steel core wire breakage sample, and class C is a wire rope addition wire breakage sample;
step 3, calculating the sum of the cross sectional areas of all steel wires in the steel wire rope, and selecting a broken wire rope type according to the step 2; respectively calculating the diameters of steel wires to be replaced in the class A and the class B according to the specified area loss amount, and calculating the diameter of the steel wire to be increased in the class C according to the specified area increase amount;
step 4, producing steel wires with corresponding diameter specifications for standby according to the steel wire diameter calculated in the step 3;
step 5, according to the calculated diameter in the step 4, for the broken wire rope sample of the class A and the class B, firstly, the replaced steel wire is extracted from the rope sample, and then the spare steel wire is added; for the C-class broken wire rope sample, straightening the steel wire rope along the length direction, disassembling the outer layer strands, adding a spare steel wire to the steel wire rope steel core, and fixing the spare steel wire between the steel core gaps;
step 6, obtaining a prepared rope sample according to the step 5, and cutting off and removing the replaced or added steel wire according to the specific wire breakage interval requirement;
and 7, fixing the steel wire at the cut-off position firmly, preventing loosening, and marking the defect position.
2. The method for manufacturing the prefabricated broken wire rope sample of the steel wire rope according to claim 1, wherein the method comprises the following steps of: in the step 1, a steel wire rope with a 16 multiplied by 19S-IWRC structure is selected, and the diameter specification of the steel wire rope is 24mm.
3. The method for manufacturing the prefabricated broken wire rope sample of the steel wire rope according to claim 1, wherein the method comprises the following steps of: in the step 3, the diameter of the steel wire in the outer layer of the outer strand of the steel wire rope which is required to be replaced in the class A is calculated, the diameter of the steel wire in the outer layer of the steel core which is required to be replaced in the class B is calculated, and the diameter of the steel wire which is required to be increased between the gaps of the steel core in the class C is calculated.
4. The method for manufacturing the prefabricated broken wire rope sample of the steel wire rope according to claim 1, wherein the method comprises the following steps of: in the step 3, the steel wire diameter is reversely calculated from the area by adopting the relation between the area and the radius of the circle.
5. The method for manufacturing the prefabricated broken wire rope sample of the steel wire rope according to claim 1, wherein the method comprises the following steps of: in the step 5, the spare steel wire is added to the steel core of the steel wire rope, and the spare steel wire is fixed between the gaps of the steel core by adopting glue.
6. The method for manufacturing the prefabricated broken wire rope sample of the steel wire rope according to claim 1, wherein the method comprises the following steps of: in the step 6, the specific wire breakage distance is 760mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310114712.5A CN116289275A (en) | 2023-02-15 | 2023-02-15 | Manufacturing method of wire rope prefabricated broken wire rope sample |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310114712.5A CN116289275A (en) | 2023-02-15 | 2023-02-15 | Manufacturing method of wire rope prefabricated broken wire rope sample |
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| CN116289275A true CN116289275A (en) | 2023-06-23 |
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| CN202310114712.5A Pending CN116289275A (en) | 2023-02-15 | 2023-02-15 | Manufacturing method of wire rope prefabricated broken wire rope sample |
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2023
- 2023-02-15 CN CN202310114712.5A patent/CN116289275A/en active Pending
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