Single-layer multi-column arrangement steel wire rope post-deformation device

Abstract

The present application belongs to the technical field of steel wire rope flexibility, and particularly relates to a single-layer multi-column arrangement steel wire rope post-deformation device. In order to eliminate or reduce the stress in the steel wire rope, improve the tensile strength, fatigue strength and impact toughness of the steel wire rope, comprehensively improve the flexibility of the steel wire rope, realize the flexibility effect on the whole circumference of the steel wire rope, and considering the complexity in the actual process, a single-layer multi-column arrangement steel wire rope post-deformation device is provided. The device mainly comprises three parallel winding drums. Each winding drum is provided with a spiral groove, and the three winding drums are connected together through synchronous toothed belts for transmission. The steel wire rope is wound in a certain mode under the driving of the winding drums, and finally the bending deformation in the whole circumferential direction of the steel wire rope is achieved.

Description

Technical Field

[0001] This invention belongs to the field of wire rope flexibility technology, and mainly relates to a device for stress relief and flexibility enhancement after wire rope manufacturing and assembly. Wire ropes are commonly used for traction and load-bearing, and are widely used in coal mining, metallurgy, petroleum, chemical, transportation, high-rise buildings, suspension bridges, and other fields. This invention specifically refers to a deformation device for single-layer, multi-row arranged wire ropes, used to eliminate or reduce stress during wire rope manufacturing and assembly, thereby improving the flexibility of the wire rope. Background Technology

[0002] Wire rope is a helical bundle of steel wires that meet the requirements of mechanical properties and geometric dimensions and are twisted together according to certain rules. Wire rope is first made by twisting multiple layers of steel wires into strands, and then twisting a certain number of strands into a helical shape with the core as the center. According to the twisting method, wire rope is classified into: (1) Single strand rope, also known as single twist rope, is made by twisting the rope-making steel wires around the central wire or hemp core, and can twist one or more layers of steel wires. (2) Double twist rope is made by twisting two strands around the core (steel core or fiber core), and can twist one or more layers of steel wires. It is the most widely used type of wire rope. (3) Triple twist rope is made by twisting double twist ropes around the core. It is mainly used for coarse steel wire ropes with a diameter of 60mm or more, such as marine steel wire ropes. This invention is aimed at triple twist rope, which is used for lifting, traction, tensioning and bearing in material handling machinery. Steel wire ropes are characterized by high strength, light weight, stable operation, and resistance to sudden breakage, ensuring reliable performance. After processing, the steel wire rope needs to be coiled into a coil on a specific drum. Therefore, a winding process is involved in the manufacturing of steel wire ropes. During winding, significant plastic deformation occurs due to the mutual compression between the steel wires. This results in internal stress within the coiled wire rope, leading to poor flexibility and difficulty in bending and coiling on the drum. The internal stress also affects the fatigue strength of the wire rope, reducing its lifespan.

[0003] The Chinese utility model patent "A Post-Deformation Device for Steel Wire Rope" (Patent No.: CN201820173489.6; Authorization Announcement No.: CN208023303U) mentions a post-deformation device for steel wire rope. This device consists of two support plates inside a housing. Three sets of guide pulleys are evenly installed on the upper support plate, and four sets are evenly installed on the lower support plate, with the upper and lower pulleys staggered. The formed steel wire rope passes through the middle, with the top of the rope contacting the bottom of the upper deformation roller and the lower deformation roller, thereby eliminating internal stress in the steel wire rope. However, because this invention can only bend the steel wire rope segment by segment, its flexibility method has a greater impact on the outer steel wires of the rope, and its flexibility effect on the internal strands of the rope is not significant, failing to achieve flexibility across the entire circumference of the steel wire rope. The Chinese invention "A Multi-Layer, Multi-Column Arrangement, Spatially Misaligned Steel Wire Rope Post-Deformation Device" (Patent No.: CN202011089049.0; Authorization Announcement No.: CN112227097A) mentions a steel wire rope post-deformation device. This device uses a multi-layer, multi-column arrangement of ordinary straight-groove drums, with two drums in each group tilted relative to each other at a certain angle to wind the steel wire rope. However, in actual processing and production, this invention has a high probability of producing defective products due to interference between the steel wire ropes inside the device. Furthermore, the multi-layer, multi-column arrangement uses a single motor to drive a single shaft, making it difficult to achieve speed synchronization between each shaft. During winding, the steel wire rope will misalign on the straight-groove drums, failing to achieve stress relief. This invention uses a synchronous toothed belt drive, with the entire device driven by a single motor, effectively solving the speed synchronization problem. Summary of the Invention

[0004] This invention aims to eliminate or reduce stress in wire ropes, improve their tensile strength, fatigue strength, and impact toughness, and comprehensively enhance their flexibility, achieving a flexible effect across the entire circumference of the wire rope. Considering the complexity of actual manufacturing processes, it proposes a single-layer, multi-row wire rope post-deformation device. This device mainly consists of three sets of parallel drums, each with a helical groove, and the three sets of drums are connected together for transmission via a synchronous toothed belt. Driven by the drums, the wire rope is wound in a specific manner, ultimately achieving bending deformation along the entire circumference of the wire rope.

[0005] A single-layer, multi-row steel wire rope deformation device assembly includes a helical gear reducer motor, a spiral drum, a drum shaft, bearings, a key, a synchronous toothed belt, and a synchronous pulley. The synchronous pulley is fitted onto the rear end of each drum shaft. The first drum shaft is connected to the helical gear reducer motor via the toothed belt. Each drum shaft inside the device is also connected to each other via a toothed belt. The spiral drum is connected to the drum shaft via a key. The rotation of the helical gear reducer motor drives the entire device to rotate via the synchronous toothed belt.

[0006] A single-layer, multi-row steel wire rope deformation device is characterized in that the device comprises three sets of parallel-arranged drum shafts, with two spiral drums having spiral grooves on their surfaces mounted on the two drum shafts of each set. The groove width and diameter of each drum in the three sets are equal, where H is the groove width (between 4mm and 5mm), d is the drum diameter (between 240mm and 260mm), and θ is the inclination angle of the spiral groove (between 10° and 14°). The three sets of parallel-arranged spiral drums are offset in position. The two spiral drums in the first set are offset vertically by a groove width. The first spiral drum in the second set is aligned with the second spiral drum in the first set, but their spiral grooves rotate in opposite directions. The second spiral drum in the second set rotates in the same direction as the first spiral drum but is offset upwards by a groove width. The first spiral drum in the third group is aligned with the second spiral drum in the second group, but their spiral grooves rotate in opposite directions. The second spiral drum in the third group rotates in the same direction as the first drum, but is offset downwards by one groove width. The first coil of wire rope is manually wound onto all the spiral drums. Then, a helical gear reducer motor drives all the drum shafts to rotate, thus rotating all the spiral drums. This winds the processed wire rope onto the three groups of drums with spiral grooves. Finally, at the rope exit end of the device, the finished product is wound around using a subsequent winding device.

[0007] The three sets of single-layer, multi-row spiral drums are housed in a sealed box, which consists of an upper box and a lower box. The lower box has wire rope inlets and outlets at both ends, with the left side being the inlet and the right side the outlet. Because a heating device is located at the bottom of the device, the wire rope inlets and outlets are kept as small as possible. The inlet is on the same plane as the first groove on the first spiral drum where the wire rope winds. The inlet diameter is a circular hole slightly larger than the wire rope diameter, with a diameter between 4 and 5 millimeters. Two small guide wheels are installed between the first drum and the left end of the box wall. One guide wheel is at the same height as the inlet, and the other is at the same height as the first spiral drum. These two guide wheels guide the wire rope to the first groove while also reducing friction between the wire rope and the box wall.

[0008] The wire rope, driven by a motor, first winds itself once on the first auger of the first group of spiral drums via a small guide wheel at the left end of the housing. Then it winds onto the second auger, then back to the first auger, repeating this process N-1 times before returning to the second group of spiral drums. The second group of spiral drums follows the same winding method as the first group: it winds itself once on the first auger, then onto the next auger, then back to the first auger, repeating this process N-1 times before returning to the third group of spiral drums. The third group follows the same method as the first two groups: it winds itself once on the first auger, then onto the second auger, then back to the first auger, repeating this process N times before the finished product is wound at the right end of the housing by a subsequent winding device.

[0009] The winding of the wire rope on the drum requires reducing friction between the wire rope and the spiral groove to decrease wear and improve the lifespan of the wire rope and the post-deformation device. This invention employs oil bath lubrication. A certain amount of lubricating oil is injected through the oil inlet of the lower housing, submerging one-third of the spiral groove drum. The overall oil temperature is controlled between 60°C and 70°C. As the drum rotates, the lubricating oil is carried throughout the entire device. Furthermore, for convenient lubricant replacement, an oil outlet and an oil inlet are located at the bottom of the housing. Because the entire device operates using an oil bath, three RYF heating tubes are installed on the lower housing, powered by DC220V with a rated power of 2000W. An intelligent temperature controller is used at the heating tube connection point, stopping heating when the heating tube reaches 80°C. Setting 80°C prevents heat dissipation during actual operation; a setting of 65°C would not achieve the optimal operating temperature.

[0010] Advantages of this invention: This invention uses a single layer of three sets of spiral groove drums to regularly wind the wire rope after winding. Compared with traditional methods, this achieves both compression and bending of the entire circumference of the wire rope and increases the number of bends, thereby comprehensively improving the local stress and flexibility of the wire rope. The housing is sealed to prevent external interference during operation, and an oil bath is used for lubrication of the entire device. A heating device is also designed to heat the lubricating oil, which better eliminates internal stress in the wire rope during lubrication. Furthermore, the entire housing occupies a small space. Attached Figure Description

[0011] Figure 1 (a) and (b) are exploded views of a single-layer, multi-row steel wire rope deformation device.

[0012] Figure 1 (c) is a set of parallel roll cross-sections.

[0013] Figure 2 Diagram showing the dimensions of the rope winding drum.

[0014] Figure 3 This is a detailed diagram showing the positional offset of the three sets of parallel drums.

[0015] Figure 4 (a) is a partial schematic diagram of the wire rope route at the rope inlet.

[0016] Figure 4 (b) is a partial schematic diagram of the direction of the wire rope at the rope outlet.

[0017] Figure 5 This is a diagram showing the overall route of the steel wire rope.

[0018] Attached reference numerals: 1-Helical gear reducer motor; 2-Synchronous toothed belt; 3-Upper housing; 4-Lower housing; 5-Rope inlet; 6-Rope inlet guide wheel; 7-Drum shaft; 8-Spiral drum; 9-Bearing; 10-Bearing end cover; 11-Screw locking retaining ring; 12-Heating tube; 13-Oil inlet; 14-Lifting lug; 15-Synchronous toothed wheel; 16-Key; 17-Rope outlet guide wheel; 18-Rope outlet; 19-Oil outlet. Detailed Implementation

[0019] The structure of the present invention will be further described below through embodiments and in conjunction with the accompanying drawings. Example

[0020] like Figure 1 As shown in (a) and (b), a single-layer, multi-row steel wire rope deformation device mainly consists of a helical gear reducer motor 1, a synchronous toothed belt 2, an upper housing 3, and a lower housing 4. The device's interior comprises six spiral drums 8 positioned in the same plane, housed within a sealed enclosure formed by the upper housing 3 and the lower housing 4. Drum shafts 7 are mounted between the upper and lower housings via bearings 9. The left and right sides of the sealed enclosure have steel wire rope inlets 5 and outlets 18, respectively. Small guide wheels 6 at the inlet and 17 at the outlet guide the steel wire rope's direction on both sides of the sealed enclosure. The sealed enclosure is sealed by bearing end caps 10.

[0021] like Figure 1 As shown in (c), the six drums are divided into three groups of two. Each group consists of two spiral drums 8 with the same spiral groove direction. Each spiral drum 8 is mounted on a drum shaft 7 and fixed by a key 16. A bearing 9 is fitted onto the drum shaft 7 and fixed between the upper and lower housings, then sealed by a bearing end cover 10. Each drum shaft has a keyless synchronous toothed wheel 15 at one end, which is connected to each other by a synchronous toothed belt 2. The first spiral drum of the first group is also connected to the helical gear reducer motor by a synchronous toothed belt 2. The entire device is driven by the helical gear reducer motor 1. During operation, the three groups of drums rotate synchronously to complete the winding of the wire rope. Figure 2 In the device shown, the groove width and diameter of the spiral drum are equal, H is the groove width of the spiral groove, d is the diameter of the drum, and θ is the inclination angle of the spiral groove.

[0022] like Figure 3As shown, the three sets of drums have certain positional offset settings. In the first set, the two spiral drums are offset vertically by a groove width. In the second set, the first spiral drum is flush with the second spiral drum of the first set, but the spiral grooves rotate in opposite directions. The second spiral drum of the second set rotates in the same direction as the first spiral drum but is offset upwards by a groove width. In the third set, the first spiral drum has spiral grooves rotating in opposite directions to the second spiral drum of the second set, and the two sets are flush. The second spiral drum of the third set rotates in the same direction as the first spiral drum but is offset downwards by a groove width. Setting these positional offsets prevents interference between adjacent grooves of the wire rope when it is wound on the drums, thereby reducing the defect rate in production.

[0023] like Figure 4 As shown in (a), the wire rope enters at the rope inlet 5 of the housing and is guided to the spiral drum 8 via a set of small guide pulleys 6. Driven by the synchronous toothed belt, the wire rope first winds around the first spiral drum of the first group once, then winds around the second spiral drum, then winds back to the first spiral drum, repeating this N-1 times from back to front to the second group. The second group follows the same winding method as the first group, first winds around the first spiral drum once, then winds around the next spiral drum, then winds back to the first spiral drum, repeating this N-1 times from back to front to the third group. The third group follows the same winding method as the first two groups, first winds around the first spiral drum once, then winds around the second spiral drum, then winds back to the first spiral drum, repeating this N-1 times, and so on. Figure 4 As shown in (b), the wire rope on the spiral drum is led out of the housing from the rope outlet 18 through a set of small guide wheels 17 at the other end. A schematic diagram of the wire rope winding inside the housing is shown below. Figure 5 As shown.

[0024] To reduce internal friction and wear, lubricating oil is injected into the lower chamber 4 of the sealed housing to a depth of one-third of the spiral drum's height. The wire rope is guided into the sealed housing via guide wheels, and each point of the wire rope passes through the lower surface of the spiral drum and is immersed in the lubricating oil, ensuring sufficient lubrication during post-deformation processing. To achieve optimal lubrication, three RYF heating elements 12 are installed in the lower chamber 4. These three heating elements are installed between three sets of parallel shafts, perfectly submerged in the lubricating oil to maintain the temperature of the oil in contact with the drum. The power supply is DC220V, with a rated power of 2000W. An intelligent temperature controller is used at the heating element's connection point, stopping heating when the heating element reaches 80℃.

[0025] When the lubricating oil in the housing needs to be changed, the old lubricating oil can be drained from the oil outlet 19. The oil outlet 19 is located on the right side wall of the lower housing and is flush with the bottom of the lower housing; this design allows for more thorough drainage of the lubricating oil. The oil inlet 13 is located on the right side wall of the lower housing for convenient lubricating oil replacement. Figure 1 As shown, the bottom and walls of the housing are designed with support structures, which greatly improves the stability of the device during operation. An observation window is designed on the surface of the upper housing for easy monitoring of the device's real-time operating status. If the wire rope is not functioning properly, it can be directly observed through the observation window, allowing for timely machine stoppage and repair. Lifting lugs 14 are designed along the edge of the upper housing surface for easy opening and inspection.

Claims

1. A single-layer, multi-row steel wire rope deformation device, characterized in that, The device includes a helical gear reducer motor, a spiral drum, a drum shaft, bearings, a key, a synchronous toothed belt, and synchronous toothed pulleys. The drum shaft consists of three sets of parallel drum shafts. Each set has two drum shafts with two spiral drums on their surfaces. The groove width and diameter of each spiral drum in the three sets are equal. The three sets of parallel spiral drums are slightly offset in position. The two spiral drums in the first set are offset vertically by the width of a groove. The first spiral drum in the second set is aligned with the second spiral drum in the first set, but their spiral grooves rotate in different directions. Conversely, the second spiral drum in the second group rotates in the same direction as the first spiral drum but is offset upwards by a groove width. The first spiral drum in the third group is aligned with the second spiral drum in the second group, but the spiral grooves rotate in opposite directions. The second spiral drum in the third group rotates in the same direction as the spiral grooves of the first drum but is offset downwards by a groove width. Synchronous toothed gears are fitted at the rear end of each drum shaft. The first drum shaft is connected to a helical gear reducer motor via a synchronous toothed belt. Each drum shaft inside the device is also connected to the others via toothed belts. The spiral drums are connected to the drum shafts via... The key connection involves manually winding the first coil of wire rope onto all the spiral drums. Then, a helical gear reducer motor drives all the drum shafts to rotate, thereby rotating all the spiral drums. This winds the processed wire rope onto three sets of spiral drums with helical grooves according to a specific winding pattern. Finally, at the rope exit end of the device, the finished product is wound around the drums using a subsequent winding device. The specific winding pattern onto the three sets of spiral drums with helical grooves refers to the wire rope first self-winding once onto the first spiral drum of the first set via a small guide wheel at the left end of the housing, driven by the motor, and then winding onto the second set of spiral drums. On two spiral drums, the winding process begins, then returns to the first spiral drum, repeating this process N-1 times before moving to the second set of spiral drums. The second set of spiral drums follows the same winding method as the first set: it winds once on the first spiral drum, then moves to the next spiral drum, then returns to the first spiral drum, repeating this process N-1 times before moving to the third set of spiral drums. The third set follows the same winding method as the first two sets: it winds once on the first spiral drum, then moves to the second spiral drum, then returns to the first spiral drum, repeating this process N times before the finished product is wound at the right end of the box by a subsequent winding device, where N≤25.

2. The single-layer, multi-row steel wire rope deformation device as described in claim 1, characterized in that, H is the width of the spiral groove, which is between 4mm and 5mm; d is the diameter of the spiral drum, which is between 240mm and 260mm; θ is the inclination angle of the spiral groove, which is between 10° and 14°.

3. The single-layer, multi-row steel wire rope deformation device as described in claim 1, characterized in that, The three sets of spiral drums arranged in a single layer and multiple rows are housed in a sealed box, which is divided into an upper box and a lower box. The lower box has wire rope inlets and outlets at both ends, with the left side being the inlet and the right side being the outlet. The inlet and the first groove on the first spiral drum are on the same plane. The diameter of the inlet is a round hole slightly larger than the diameter of the wire rope, with a diameter between 4 and 5 millimeters. Two small guide wheels are installed between the first drum and the left end of the box wall. One guide wheel is at the same height as the inlet, and the other guide wheel is at the same height as the first spiral drum. The two small guide wheels guide the wire rope to the first groove and also reduce the friction between the wire rope and the box wall.

4. The single-layer, multi-row steel wire rope deformation device as described in claim 3, characterized in that, The surface of the upper housing is designed with an observation window to facilitate observation of the real-time working status of the device. If the wire rope wound by the device is in an abnormal working state, it can be seen directly through the observation window, allowing for timely machine repair. The surface edge of the upper housing is designed with lifting lugs for easy opening and inspection.

5. The single-layer, multi-row steel wire rope deformation device as described in claim 1, characterized in that, Oil bath lubrication is adopted. A certain amount of lubricating oil is injected through the oil inlet of the lower chamber, and the lubricating oil submerges 1 / 3 of the spiral groove drum. The overall oil temperature is controlled between 60℃ and 70℃. As the drum rotates, the lubricating oil is carried into the entire device. In addition, for easy replacement of lubricating fluid, there is an oil outlet and an oil inlet at the bottom of the chamber. Three RYF heating tubes are installed on the lower chamber. The power supply for the heating tubes is DC220V, and the rated power is 2000W. An intelligent temperature controller is used at the wiring of the heating tubes. Heating is stopped when the heating temperature of the heating tubes reaches 80℃.

6. The single-layer, multi-row steel wire rope deformation device as described in claim 5, characterized in that, The oil outlet is located on the right side wall of the lower housing and is flush with the bottom of the lower housing. This design allows the lubricating oil to be discharged more thoroughly. The oil inlet is located on the right side wall of the lower housing for easy replacement of the lubricating oil. Three heating tubes are installed between the three sets of parallel shafts, and the heating tubes are just submerged in the lubricating oil to ensure the temperature of the oil in contact with the drum.

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