A method for manufacturing a solid polymer filled steel wire rope

Abstract

The application discloses a kind of solid polymer filled steel wire rope manufacturing method, the device used by the method includes conveying mechanism, heavy twist mechanism and output mechanism, specific operation steps are as follows: a, the input of steel wire rope: through the conveying mechanism, steel wire rope is conveyed to heavy twist mechanism inside;B, the separation of steel wire rope: through the heavy twist mechanism, steel wire rope is opened;C, the re-twist of separated steel wire rope: through the heavy twist mechanism, filler is filled to the inside of the opened steel wire rope, and after filling, the opened steel wire rope is re-twisted;D, the output of re-twisted steel wire rope: after re-twist, steel wire rope is conveyed through output mechanism, and the winding of re-twisted steel wire rope is realized.The application has good filling effect, and fully protects strand rope and steel wire;It is simple and convenient to operate, greatly reduces the difficulty of manufacturing process and tool design, and is beneficial to universal popularization.

Description

Technical Field

[0001] This invention relates to the field of steel wire rope manufacturing technology, and in particular to a method for manufacturing a solid polymer-filled steel wire rope. Background Technology

[0002] Currently, the main methods for manufacturing solid polymer-filled steel wire ropes include injection, extrusion, and pre-forming of the plastic layer. This patented method involves re-twisting the steel wire rope to fill it with solid polymer, completely filling and isolating the gaps between the core and strands, and between strands themselves. This reduces mutual wear between the wires and improves the service life of the steel wire rope. Summary of the Invention

[0003] The purpose of this invention is to provide a method for manufacturing a solid polymer-filled steel wire rope to solve the problems existing in the prior art. The method has a good filling effect, provides sufficient protection for the strands and steel wires, and is simple and convenient to operate. It greatly reduces the difficulty in manufacturing process and tooling design, which is conducive to its widespread application.

[0004] To achieve the above objectives, the present invention provides the following solution: The present invention provides a method for manufacturing solid polymer-filled steel wire rope. The apparatus used in this method includes a conveying mechanism, a re-twisting mechanism, and an output mechanism. The specific operating steps are as follows:

[0005] a. Input of wire rope: The wire rope is fed into the re-twisting mechanism via the conveying mechanism;

[0006] b. Separation of the wire rope: The wire rope is opened by the retwisting mechanism;

[0007] c. Retwisting of the separated wire rope: The retwisting mechanism fills the inside of the open wire rope with filler material, and after filling, the open wire rope is retwisted.

[0008] d. Output of re-twisted wire rope: The re-twisted wire rope is conveyed through the output mechanism to realize the winding of the re-twisted wire rope.

[0009] Preferably, in step a, the conveying mechanism includes a rotating wire feeding frame, a first traction machine, and an induction coil. When the wire rope is conveyed, the wire rope is placed on the rotating wire feeding frame, and the wire rope enters the induction coil after passing through the first traction machine, and then enters the re-twisting mechanism after passing through the induction coil.

[0010] Preferably, in step b, the retwisting mechanism includes a retwisting device, the wire rope passes through the retwisting device, and the wire rope is in an open state through the retwisting device.

[0011] Preferably, the output mechanism includes a cooling device, a second traction machine, and a take-up device. After the wire rope is cooled by the cooling device, it is transported to the take-up device by the second traction machine, and the take-up device completes the winding process.

[0012] Preferably, the rotating wire feeding frame is provided with an I-beam reel, and the wire rope is wound around the I-beam reel; the rotating wire feeding frame is a damped rotating wire feeding frame.

[0013] Preferably, the wire rope is preheated by the induction coil.

[0014] Preferably, the retwisting device includes a base, a support plate fixedly connected to the top of the base, a separating disc rotatably connected to the support plate, a plurality of tensioning wheels fixedly connected circumferentially to the separating disc, the spacing between adjacent tensioning wheels being equal, a separating rod provided in the middle of the separating disc, two separating blocks symmetrically fixedly connected to both ends of the separating rod, the distance between the two separating blocks, the adjustment height of the tensioning wheels, and the twisting parameters of the wire rope being consistent, the wire rope including a core and an outer strand, through holes provided on the separating rod and the separating blocks, the through holes on the separating rod communicating with the through holes on the separating blocks, the core corresponding to the through holes, the outer strands corresponding to the tensioning wheels, and a motor fixedly connected to the support plate, the motor being drivenly connected to the separating disc.

[0015] Preferably, an extruder is provided at the end of the retwisting device away from the conveying mechanism, the extruder contains polymer material, the extruder is fixedly connected to a die head, and the output end of the die head extends between the two outer strands.

[0016] Preferably, the cooling device is provided with a cooling water tank containing coolant, a drain outlet is provided on one side of the bottom of the cooling device, and a collection tank is provided below the cooling device, with the drain outlet corresponding to the collection tank.

[0017] This invention discloses the following technical advantages: The invention provides a method for manufacturing a solid polymer-filled steel wire rope. This method offers excellent filling performance by re-twisting the steel wire rope for filling and opening it up. This ensures that the filler material can more easily enter the interior of the steel wire rope, filling the gaps between the strands and the wires, thus providing ample protection for the strands and wires. The operation is simple and convenient. Existing methods are very difficult to implement, requiring high standards for the fluidity of the filler material, the conformity of the pre-formed groove shape, and the precision of the mold. This method significantly reduces the difficulty of the manufacturing process and tooling design, facilitating widespread adoption. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the production line layout structure of the present invention;

[0020] Figure 2 This is a schematic diagram of the wire rope re-twisting process of the present invention;

[0021] Figure 3 This is a schematic diagram of the re-twisted state of the wire rope according to the present invention;

[0022] Among them, 1-rotating pay-off frame; 2-first traction machine; 3-induction coil; 4-retwisting device; 41-tensioning wheel; 42-separating rod; 43-separating block; 44-base; 45-support plate; 46-separating disc; 47-motor; 5-cooling device; 6-second traction machine; 7-reeling device; 8-rope core; 9-outer strand; 10-machine head; 11-extruder; 12-liquid collection tank; 13-drain outlet. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0025] This invention provides a method for manufacturing solid polymer-filled steel wire rope. The apparatus used in this method includes a conveying mechanism, a re-twisting mechanism, and an output mechanism. The specific operating steps are as follows:

[0026] a. Input of wire rope: The wire rope is fed into the re-twisting mechanism via a conveying mechanism;

[0027] b. Retwisting of wire rope: The wire rope is opened by the retwisting mechanism, the filler is filled into the internal space of the wire rope, and the wire rope is retwisted after filling.

[0028] c. Output of wire rope: The wire rope is wound up after being conveyed by the output mechanism. a. Input of wire rope: The wire rope is conveyed to the re-twisting mechanism through the conveying mechanism.

[0029] b. Separation of the wire rope: The wire rope is opened by the retwisting mechanism;

[0030] c. Retwisting of the separated wire rope: The retwisting mechanism fills the inside of the open wire rope with filler material, and after filling, the open wire rope is retwisted.

[0031] d. Output of re-twisted wire rope: The re-twisted wire rope is conveyed through the output mechanism to realize the winding of the re-twisted wire rope.

[0032] To further optimize the scheme, in order to ensure the input of the wire rope by the conveying mechanism, in step a, the conveying mechanism includes a rotating wire feeding frame 1, a first traction machine 2, and an induction coil 3. When the wire rope is conveyed, the wire rope is placed on the rotating wire feeding frame 1. The wire rope enters the induction coil 3 through the first traction machine 2 and then enters the re-twisting mechanism. The induction coil 3 preheats the wire rope. The wire rope is fed out by the first traction machine 2 while providing a certain reverse tension.

[0033] To further optimize the scheme, in order to achieve the re-twisting of the wire rope, in step b, the re-twisting mechanism includes a re-twisting device 4, the wire rope passes through the re-twisting device 4, and the wire rope passes through the re-twisting device 4 in an open state.

[0034] To further optimize the scheme, in order to ensure the transportation, winding and storage of the wire rope after retwisting, the output mechanism includes a cooling device 5, a second traction machine 6, and a winding device 7. In order to quickly fix the retwisted wire rope and ensure its stability, the wire rope is cooled by the cooling device 5 and then transported to the winding device 7 by the second traction machine 6, where the winding process is completed.

[0035] To further optimize the scheme and ensure stable wire rope delivery, the rotating wire rope feeder 1 is equipped with an I-beam wheel, and the wire rope is wound around the I-beam wheel. The rotating wire rope feeder 1 is a damped rotating wire rope feeder.

[0036] To further optimize the solution and improve the separation effect of the wire rope while reducing the separation difficulty, the wire rope is preheated by induction coil 3.

[0037] To further optimize the design and achieve separation and retwisting of the wire rope, the retwisting device 4 includes a base 44. A support plate 45 is fixedly connected to the top of the base 44. A separating disc 46 is rotatably connected to the support plate 45. Several tensioning rollers 41 are fixedly connected to the separating disc 46 along its circumference. The distance between adjacent tensioning rollers 41 is equal. A separating rod 42 is set in the middle of the separating disc 46. The separating rod 45 is fixedly connected to the separating disc 46. The rotation of the separating disc 46 drives the separating rod 42 to rotate synchronously. Two separating blocks 43 are symmetrically fixedly connected to both ends of the separating rod 42. To ensure the separation and retwisting effect, the distance between the two separating blocks 43 and the tensioning rollers 41 are adjusted. The section height and wire rope twisting parameters are kept consistent. The end of the separating block 43 away from the separating rod 42 is hemispherical. The wire rope includes a core 8 and an outer strand 9. Both the separating rod 42 and the separating block 43 have through holes. The through holes on the separating rod 42 are connected to the through holes on the separating block 43. The core 8 is set in accordance with the through holes, and the outer strand 9 is set in accordance with the tension wheel 41. In order to further ensure the effect and efficiency of wire rope separation and retwisting, both separating blocks 43 have rotary grooves. The grooves are set in accordance with the wire rope separation and twisting. A motor 47 is fixedly connected to the support plate 45. The motor 47 is connected to the separating disc 46 for transmission.

[0038] To further optimize the scheme, in order to fill the separated steel wire rope with solid polymer, an extruder 11 is set at the end of the retwister 4 away from the conveying mechanism. The extruder 11 is filled with polymer material. The extruder 11 is fixedly connected to the die head 10. The output end of the die head 10 extends between the two outer strands 9.

[0039] To further optimize the design, in order to ensure the rapid shaping of the re-twisted wire rope and the stability of the solid polymer inside the wire rope, a cooling water tank is provided in the cooling device 5, which contains coolant. In order to realize the recycling of coolant and avoid resource waste, a drain port 13 is provided on one side of the bottom of the cooling device 5, and a collection tank 12 is provided below the cooling device 5. The drain port 13 and the collection tank 12 are correspondingly set.

[0040] refer to Figure 1The process of manufacturing solid polymer-filled steel wire rope using the retwisting method of the present invention involves placing the steel wire rope on an I-beam reel on a rotating pay-off frame 1. One end of the steel wire rope passes through a first traction machine 2 and enters an induction coil 3. The induction coil 3 preheats the steel wire rope to facilitate its separation later. After preheating, the steel wire rope enters a retwisting machine 4, where it is separated and then retwisted. During the retwisting process, solid polymer is filled into the separated steel wire rope through an extruder 11. After retwisting, the separated steel wire rope passes through a cooling device 8, where the coolant cools the retwisted steel wire rope. The newly twisted steel wire rope, after cooling, is transported to a take-up device 7 by a second traction machine 6. The take-up device 7 then winds up the newly twisted steel wire rope.

[0041] refer to Figure 2 The process of retwisting and polymer filling of the steel wire rope according to the present invention is as follows: The steel wire rope is retwisted by the retwisting machine 4, wherein the core 8 of the steel wire rope is introduced into the retwisting machine 4 and led out through the center of the separating block 43 and the separating rod 42. After separation, the outer strands 9 of the steel wire rope are separated by the separating block 43 and the tensioning wheel 41. The motor 47 drives the separating disc 46 to rotate, the separating disc 46 drives the separating rod 42 to rotate synchronously, and the separating rod drives the two separating blocks 43 to rotate. The separating blocks 43 have grooves corresponding to the outer strands 9. The grooves on the two separating blocks 43 are correspondingly arranged. When separating the steel wire rope, the separating blocks 43 rotate so that the outer strands 9 coincide with the grooves, further improving the efficiency. To improve the separation efficiency and effect of the wire rope, when the other separating block 43 rotates to retwist the separated wire rope, the groove on the separating block 43 overlaps with the outer strand 9, driving the outer strand 9 to twist, further improving the twisting effect. The distance between the two separating blocks 43 and the adjustment height of the tension wheel 41 need to be consistent with the twisting parameters of the wire rope. At the same time, the height of the tension wheel 41 is adjustable to adapt to wire ropes of various specifications and sizes, ensuring the separation and retwisting of the wire rope. The core 8 and the outer strand 9 of the wire rope are retwisted in the extruder 11 and combined together. The die head 10 of the extruder 11 fills the separated outer strand 9 with solid polymer.

[0042] refer to Figure 3 This is a schematic diagram of the retwisted state of the steel wire rope of the present invention. The steel wire rope is opened by several tensioning pulleys 41, and the core 8 and the outer strands 9 of the steel wire rope are separated, creating a space inside the steel wire rope. Solid polymer is then filled into the internal space of the steel wire rope to effectively separate the core 8 and the outer strands 9 of the steel wire rope, thus completing the production of the solid polymer-filled steel wire rope.

[0043] This invention provides a method for manufacturing a solid polymer-filled steel wire rope. The method offers excellent filling performance by re-twisting the steel wire rope and opening it up, ensuring the filler penetrates more easily into the rope and fills the gaps between the strands and wires, thus providing ample protection for both. The method is simple and convenient to operate, whereas previous methods were extremely difficult, requiring high precision in filler flowability, conformity of the pre-formed groove shape, and mold accuracy. This method significantly reduces the difficulty of the manufacturing process and tooling design, facilitating widespread adoption.

[0044] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0045] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A method of manufacturing a solid polymer filled steel wire rope, characterized by, The device used in the method comprises a conveying mechanism, a re-twisting mechanism and an output mechanism, and the specific operation steps are: a. Input of the steel wire rope: the steel wire rope is conveyed into the re-twisting mechanism through the conveying mechanism; b. Separation of the steel wire rope: the steel wire rope is opened through the re-twisting mechanism; c. Re-twisting of the separated steel wire rope: filler is filled into the opened steel wire rope through the re-twisting mechanism, and the opened steel wire rope is re-twisted after the filling is completed; d. Output of the re-twisted steel wire rope: the re-twisted steel wire rope is conveyed through the output mechanism to realize the winding of the re-twisted steel wire rope. In step b, the re-twisting mechanism comprises a re-twister (4), and the steel wire rope is in an opened state through the re-twister (4). The re-twister (4) comprises a base (44), a support plate (45) fixedly connected to the top end of the base (44), a separation disc (46) rotatably connected to the support plate (45), a plurality of tensioning wheels (41) fixedly connected to the separation disc (46) in a circumferential direction, adjacent two tensioning wheels (41) having equal spacing, a separation rod (42) provided in the middle of the separation disc (46), the separation rod (42) being fixedly connected to the separation disc (46), two separation blocks (43) fixedly connected to the two ends of the separation rod (42) in a symmetrical manner, the steel wire rope comprising a core (8) and an outer layer strand (9), through holes being formed in the separation rod (42) and the separation blocks (43), the through holes in the separation rod (42) being in communication with the through holes in the separation blocks (43), the core (8) being provided correspondingly to the through holes, the outer layer strand (9) being provided correspondingly to the tensioning wheels (41), a motor (47) being fixedly connected to the support plate (45), the motor (47) being in transmission connection with the separation disc (46), rotation type grooves being formed in the two separation blocks (43) and being provided correspondingly to the separation and twisting of the steel wire rope.

2. A method of manufacturing a solid polymer filled steel wire rope according to claim 1, characterized in that: In step a, the conveying mechanism comprises a rotating pay-off stand (1), a first traction machine (2) and an induction coil (3), the steel wire rope is provided on the rotating pay-off stand (1) during conveying, the steel wire rope enters the induction coil (3) through the first traction machine (2), and enters the re-twisting mechanism through the induction coil (3).

3. The method of manufacturing a solid polymer filled wire rope according to claim 1, wherein: The output mechanism comprises a cooling device (5), a second traction machine (6) and a take-up device (7), the steel wire rope is conveyed to the take-up device (7) through the second traction machine (6) after being cooled by the cooling device (5), and the winding process is completed through the take-up device (7).

4. The method of manufacturing a solid polymer filled wire rope according to claim 2, wherein: A I-shaped wheel is provided on the rotating pay-off stand (1), the steel wire rope is wound on the I-shaped wheel, and the rotating pay-off stand (1) is a damping rotating pay-off stand.

5. The method of manufacturing a solid polymer filled wire rope according to claim 2, wherein: The steel wire rope is preheated through the induction coil (3).

6. The method of manufacturing a solid polymer filled wire rope according to claim 1, wherein: The heavy twister (4) is provided with an extruder (11) away from one end of the conveying mechanism, the extruder (11) is provided with polymer material, the extruder (11) is fixedly connected with a machine head (10), and the output end of the machine head (10) extends into between the two outer layer strands (9).

7. The method of manufacturing a solid polymer filled wire rope according to claim 3, characterized in that: The cooling device (5) is provided with a cooling water tank, the cooling water tank is provided with cooling liquid, the bottom end of the cooling device (5) is provided with a liquid outlet (13), the cooling device (5) is provided with a liquid collecting tank (12) below, and the liquid outlet (13) is arranged correspondingly with the liquid collecting tank (12).

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