A casting method for improving the internal quality of cable joints using ultrasonic vibration.

Abstract

This invention provides a casting method for improving the internal quality of cable joints using ultrasonic vibration, comprising the following steps: Step S1: Spreading one end of a steel wire rope into a bundle of wires; Step S2: Inserting the bundle of wires into a cylindrical casting body; Step S3: Selecting multiple wires and combining them into a single strand, which is then connected to the transducer of an ultrasonic vibration device; Step S4: Starting the ultrasonic vibration device and pouring liquid casting material into the casting body; Step S5: Stopping the ultrasonic vibration, repairing the cable joint, and completing the process. This invention utilizes a portion of the steel wires from the steel wire rope itself within the casting body as an oscillator for ultrasonic vibration, thereby fully transmitting vibration energy to the root of the joint. This significantly improves the filling density of the casting material at the root of the casting body, substantially enhancing the internal casting quality of the cable joint, particularly the casting quality at the root of the joint.

Description

Technical Field

[0001] This invention belongs to the field of steel wire rope joint manufacturing technology, specifically a casting method that uses ultrasonic vibration to improve the internal quality of the cable joint casting. Background Technology

[0002] Wire rope slings serve various functions, including hoisting, traction, tensioning, and load-bearing, and are widely used in industrial production and daily life. Rigging joints, also known as cable couplings, require a secure connection between the cable coupling and the end of the wire rope during manufacturing. This ensures a reliable connection between the cable coupling and the pulled component during use. To guarantee the load-bearing capacity of the cable coupling, a secure connection between the cable coupling and the wire rope is essential. Currently, casting is commonly used to connect the cable coupling and the wire rope. However, during the casting process, the gaps between the wires at the bottom of the casting are relatively small, making it difficult to completely fill these gaps after the casting material is poured into the casting cavity, especially at the bottom. Therefore, the weakest point of the cast cable coupling under tension is the bottom area of ​​the casting, resulting in a lower breaking strength compared to the wire rope itself.

[0003] Currently, to improve the breaking strength of cast cable joints, one method is to increase the internal volume of the casting, thereby increasing the gap between the steel wires at the root of the casting and thus increasing the filling of the casting material at the root of the joint, thereby improving the internal quality of the cable joint. This method increases the volume of the cable joint. Another method is to fill the cable joint with inert gases such as argon during the casting process to expel gases at the root of the joint and improve the internal quality of the joint. However, in inert gas protected casting, due to the instability of the airflow direction within the casting, it is impossible to completely expel all gases and impurities from the casting to the surface of the liquid. Therefore, the internal quality of cable joints cast using this method is still slightly inferior, and a small number of internal pores may appear.

[0004] Ordinary ultrasonic vibration methods cannot achieve vibration casting because the amplitude transformer is too thick to reach the root of the casting with very small gaps, and the effective distance of ultrasonic vibration is very small, so the vibration energy cannot be transmitted to the root of the casting. Summary of the Invention

[0005] To address the aforementioned problems in the existing technology, the purpose of this invention is to provide a casting method that uses ultrasonic vibration to improve the internal quality of cable joint casting. During casting, a portion of the steel wires of the steel wire rope itself within the casting body is used as an oscillator for ultrasonic vibration, thereby fully transmitting the vibration energy to the root of the joint. This significantly improves the filling degree of the casting material at the root of the casting body, greatly enhancing the internal casting quality of the cable joint, especially the casting quality at the root of the cable joint.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0007] A casting method for improving the internal quality of cable joint casting using ultrasonic vibration includes the following steps:

[0008] Step S1: Untangle one end of the wire rope into a bundle of wires;

[0009] Step S2: Insert the loose bundle of steel wire into the cylindrical casting;

[0010] Step S3: Select multiple steel wires, combine them into one, and connect it to the transducer of the ultrasonic vibration device.

[0011] Step S4: Start the ultrasonic vibration device and pour the liquid casting material into the casting body;

[0012] Step S5: Stop the ultrasonic testing, repair the cable connector, and the processing is complete.

[0013] As a further improvement to the above technical solution:

[0014] Step S1 includes the following steps:

[0015] Step S11: Secure the wire rope at a predetermined distance near one end;

[0016] Step S12: Untie all the wires from the binding point to the end of the wire rope into a bundle;

[0017] Step S13: Keep several steel wires uncut and cut the other loose steel wires to the length required for the cable joint.

[0018] Multiple uncut steel wires should not be placed next to each other.

[0019] In step S11, thin iron wire is used for binding and fixing.

[0020] One or more wires in each strand of steel wire are left uncut.

[0021] Step S2 includes the following steps:

[0022] Step S21: Clean the loose bundle of steel wire and the casting.

[0023] Step S22: Insert all the steel wires from the binding point to the end into the casting body from the bottom upwards;

[0024] Step S23: Seal the gap between the bottom of the casting and the wire rope.

[0025] In step S23, the gap between the lower end of the casting and the wire rope is sealed with asbestos cloth.

[0026] In step S3, the ultrasonic vibration device includes a transducer and an amplitude transformer connected to the transducer, with multiple steel wires connected together as a single strand and connected to the amplitude transformer.

[0027] Step S4 includes the following steps:

[0028] Step S41: Preheat the casting and the loose steel wires inside;

[0029] Step S42: Start the ultrasonic vibration device;

[0030] Step S43: Pour the liquid casting material into the casting body in one go.

[0031] In step S5, after the root of the cable joint is filled with casting material, the ultrasonic vibration equipment is stopped. After the ultrasonic vibration equipment is stopped, the cast cable joint is cooled to the required temperature and then repaired to meet the usage requirements.

[0032] The beneficial effects of this invention are:

[0033] 1) During casting, ultrasonic vibration is performed by using part of the steel wires of the steel wire rope itself in the casting body as a vibrator to fully transmit the vibration energy to the root of the joint, which greatly improves the filling of the casting material at the root of the casting body and significantly improves the internal casting quality of the cable joint, especially the casting quality at the root of the cable joint.

[0034] 2) It is easy and simple to operate and has low cost. The vibration is transmitted through the ultrasonic vibration device and part of the steel wires of the steel wire rope itself. There is no need to insert the amplitude transformer directly into the casting body. This avoids the problem that the thicker amplitude transformer cannot be inserted into the dense area of ​​the steel wires at the root of the casting body, resulting in an insignificant filling effect of the casting material at the root. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of a structure according to an embodiment of the present invention.

[0036] Reference numerals: 1. Wire rope; 2. Asbestos cloth; 3. Thin iron wire; 4. Spreading wire; 5. Casting body; 6. Casting material; 7. Gating and riser; 8. Elongating wire; 9. Connecting sleeve; 10. Amplitude bar; 11. Fixing plate; 12. Transducer. Detailed Implementation

[0037] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0038] For ease of description, spatial relative terms such as "above," "on top of," "on the upper surface of," "above," etc., are used herein to describe the spatial positional relationship of a device or feature as shown in the figures to other devices or features. It should be understood that spatial relative terms are intended to encompass different orientations in use or operation beyond the orientation of the device as described in the figures. For example, if the device in the figures were inverted, a device described as "above" or "on top of" other devices or structures would subsequently be positioned as "below" or "under" other devices or structures. Thus, the exemplary term "above" can include both "above" and "below." The device may also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0039] A casting method for a wire rope joint, wherein the wire rope 1 is made of multiple strands of steel wire twisted together, and each strand of steel wire includes multiple steel wires, such as... Figure 1 As shown, the casting method includes the following steps:

[0040] Step 1: Tie and secure the steel wire rope 1 at a set distance near one end.

[0041] In this step, thin iron wire 3 is used for binding and fixing.

[0042] In this embodiment, the diameter of the steel wire rope 1 used is φ37mm, and it is a hemp-core steel wire rope 1. The selected setting distance is 260mm. The diameter of the selected binding wire 3 is φ1.2mm.

[0043] In this embodiment, the hemp core inside the wire rope 1 is first cut off at a position 260mm from one end of the wire rope 1, and then a thin iron wire 3 is used to tie 30 turns from the cut hemp core towards the end of the wire rope 1.

[0044] Step 2: Untie all the wires from the binding point to the end of the wire rope 1 into a bundle.

[0045] In this step, the length of the dispersed steel wire is determined based on the frequency of the ultrasonic vibration equipment, the diameter of the steel wire, and the weight of the casting 5.

[0046] In this embodiment, the end of the steel wire rope 1 is spread out and straightened into a bundle of spread steel wires.

[0047] Step 3: Cut the wire rope 1, which has been unfurled into a bundle of wires, to the length required for the knot, leaving several wires uncut.

[0048] In this step, the multiple uncut steel wires are not sequentially adjacent. Preferably, one or several steel wires in each strand are left uncut. The number of steel wires left in each strand is determined by the interface size of the transducer 12 and the total number of steel wires in the steel rope 1. Let the uncut steel wires be called extended steel wires and the cut steel wires be called spread steel wires. The spread steel wires 4 and extended steel wires 8 are shown in the attached figure.

[0049] In this embodiment, the required length of the cable joint is 140mm, that is, the steel wire is cut to a length of 140mm.

[0050] In this embodiment, the central wire of each strand is retained without being cut short.

[0051] Step 4: Clean the loose bundle of steel wire and casting 5 thoroughly.

[0052] In this embodiment, the scattered steel wires are sandblasted and then cleaned with alcohol. If they can be cleaned with alcohol, sandblasting is unnecessary.

[0053] In this embodiment, a riser 7 is used. The casting body 5 and the riser 7 are sandblasted and cleaned with alcohol, and then connected as one unit, with the riser 7 connected to the upper end of the casting body 5. Both the casting body 5 and the riser 7 are cylindrical structures. After the riser 7 and the casting body 5 are connected, the riser 7 and the casting body 5 share the same center line.

[0054] Step 5: Insert all the steel wires from the binding point to the end into the casting body 5 from the bottom upwards.

[0055] In this step, before inserting the loose steel wire into the casting 5, the loose steel wire and the inner cavity of the casting 5 can be coated with flux or immersed in flux.

[0056] In this step, the elongated steel wire 8 passes through the casting body 5, while the unfurled steel wire 4 does not pass through the casting body 5 but is inserted into the casting body 5 for a certain length. Preferably, the cut steel wire 4 is entirely located inside the casting body 5 from the binding point to the end.

[0057] Step 6: Seal the gap between the bottom of the casting 5 and the wire rope 1.

[0058] In this step, the lower end of the casting 5 is wrapped with asbestos cloth 2 at the contact point with the wire rope 1 to achieve a sealed gap.

[0059] Step 7: Combine the multiple uncut steel wires into one strand and connect it to the transducer 12 of the ultrasonic vibration device.

[0060] In this step, the ultrasonic vibration device includes a transducer 12, an amplitude transformer 10, and a connecting sleeve 9. The upper end of the amplitude transformer 10 is connected to the transducer 12, and the lower end is connected to the connecting sleeve 9. Multiple steel wires that are combined into one strand and not cut short are connected to the connecting sleeve 9.

[0061] In this embodiment, the transducer 12 is supported on the fixed plate 11, and the amplitude transformer 10 is connected to the transducer 12 through the fixed plate 11. The connecting sleeve 9 is located above the cable connector.

[0062] Step 8: Preheat the casting 5 and the scattered steel wires inside.

[0063] In this step, the casting 5 can be preheated by means of flame heating, induction heating or resistance heating.

[0064] In this embodiment, flame heating is used to heat the casting 5, the riser 7, and the internal spreading steel wires.

[0065] Step 9: Start the ultrasonic vibration device.

[0066] Step 10: Pour the liquid casting material 6 into the casting body 5 in one go.

[0067] Step 11: Stop the ultrasonic testing, repair the cable connector, and the processing is complete.

[0068] After preheating the casting 5, ultrasonic vibration is initiated when the liquid casting material 6 is to be poured in. After the ultrasonic vibration ends, heating of the casting 5 is stopped. Once the cast cable joint has cooled to room temperature, the ends of the cable joint are trimmed to meet product requirements. The liquid casting material 6 is poured in through the gating system 7. The casting material 6 can be made from materials available in the prior art.

[0069] In this embodiment, the ultrasonic vibration ends when no oxide inclusions float to the surface inside the riser 7.

[0070] In this embodiment, when repairing the cable joint, the riser 7 is cut off and the cut surface is repaired. The cast body 5 is fixedly connected to the casting material 6 and the steel wire to form the cable joint.

[0071] Finally, it is necessary to state that the above embodiments are only used to further illustrate the technical solution of the present invention in detail, and should not be construed as limiting the scope of protection of the present invention. Any non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention shall fall within the scope of protection of the present invention.

Claims

1. A casting method for improving the internal quality of a cast cable joint by ultrasonic vibration, characterized by, It comprises the following steps: Step S1: spread the steel wire rope at one end into a bundle of steel wires; Step S2: insert the spread bundle of steel wires into a cylindrical casting body; Step S3: select a plurality of steel wires to combine into a strand and connect to the transducer of the ultrasonic vibration device; Step S4: start the ultrasonic vibration device and pour liquid casting material into the casting body; Step S5: stop the ultrasonic vibration, repair the cable joint, and complete the processing; Step S1 comprises the following steps: Step S11: bind and fix the steel wire rope at a distance close to the end; Step S12: spread all the steel wires from the binding place to the end of the steel wire rope into a bundle of steel wires; Step S13: retain a plurality of steel wires without cutting, and cut the other steel wires to the required length of the cable joint; The plurality of steel wires not cut do not follow each other in turn, and one or several steel wires are retained in each strand without cutting.

2. The casting method according to claim 1, characterized by: In step S11, a thin iron wire is used for binding and fixing.

3. The casting method according to claim 1, characterized by: Step S2 comprises the following steps: Step S21: clean the spread bundle of steel wires and the casting body; Step S22: insert all the steel wires from the binding place to the end of the steel wire rope into the casting body from the bottom of the casting body; Step S23: seal the gap between the bottom of the casting body and the steel wire rope.

4. The casting method according to claim 3, characterized by: In step S23, the gap is sealed by wrapping the contact part of the lower end of the casting body with the steel wire rope with asbestos cloth.

5. The casting method according to claim 1, characterized by: In step S3, the ultrasonic vibration device comprises a transducer and a horn connected to the transducer, and the plurality of steel wires combined into a strand are connected to the horn.

6. The casting method according to claim 1, characterized by: Step S4 comprises the following steps: Step S41: preheat the casting body and the spread steel wires inside; Step S42: start the ultrasonic vibration device; Step S43: pour the liquid casting material into the casting body at one time.

7. The casting method according to claim 1, characterized by: In step S5, the ultrasonic vibration device is stopped after the root of the cable joint is filled with casting material, and the cooled cable joint is cooled to the required temperature before being repaired to meet the use requirements.

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