A method for processing steel wire rope for wind turbine tower and steel wire

Abstract

The invention belongs to the technical field of steel wire rope processing, and proposes a steel wire rope processing method and steel wire for a wind turbine tower, comprising: determining the steel wire diameter and corrosion resistance time of the steel wire rope to be processed according to the requirements of the steel wire rope for the wind turbine tower; calculating the weight of the steel wire zinc layer according to the determined steel wire diameter and corrosion resistance time; and processing the steel wire by taking the determined steel wire diameter and the calculated steel wire zinc layer weight as processing parameters. The invention first determines the steel wire diameter and corrosion resistance time of the steel wire rope to be processed according to the requirements of the steel wire rope for the wind turbine tower, thereby ensuring the corrosion resistance and strength requirements for the processed steel wire rope; then, calculating the weight of the steel wire zinc layer according to the determined steel wire diameter and corrosion resistance time, and processing and putting into production a large number of steel wires by taking the determined steel wire diameter and the calculated steel wire zinc layer weight as processing parameters, without the need for neutral salt spray test and mechanical test, thereby greatly reducing the production cost and production cycle.

Description

Technical Field

[0001] The invention belongs to the technical field of steel wire rope processing, and in particular relates to a steel wire rope processing method and steel wire for a wind turbine tower. Background Art

[0002] The corrosion resistance of steel wire rope is evaluated according to the neutral salt spray test method in GB / T 10125-2012 standard. The test requires cutting samples from the produced steel wire rope and using a salt spray test machine in a specified salt spray environment. According to the operating conditions of steel wire ropes for wind turbine towers, the corrosion resistance of steel wire ropes should reach the neutral salt spray test time of 240 to 720 hours without red rust. Before the production of steel wire ropes, the weight of the zinc layer of the steel wire needs to be determined to meet the corrosion resistance requirements of the final steel wire rope products.

[0003] The inventors found that in the processing technology of steel wire ropes for wind turbine towers, the traditional practice is to first process small batches of steel wire ropes, cut test samples from the small batches of steel wire ropes, conduct neutral salt spray tests, mechanical tests, etc. on the test samples, and only when the test data meets the requirements will mass production be carried out. When the test data does not meet the requirements, it is necessary to adjust the zinc layer weight and diameter of the steel wire and then conduct tests again until the test data meets the requirements; and before mass production, neutral salt spray tests and mechanical properties tests are carried out. Once the test data does not meet the standards, the small batches of steel wire ropes produced in the early stage become waste, which brings great waste to the enterprise, and the tests, especially repeated tests, require corresponding test equipment assistance and a longer test time, which brings costs to the production of the steel wire ropes and increases the production cycle. Summary of the invention

[0004] In order to solve the above problems, the present invention provides a method for processing a steel wire rope for a wind turbine tower and a steel wire, which reduces production costs and production cycles while meeting performance requirements of the steel wire rope under different working conditions.

[0005] In order to achieve the above-mentioned object, in a first aspect, the present invention provides a method for processing a steel wire rope for a wind turbine tower, which adopts the following technical scheme:

[0006] A method for processing a steel wire rope for a wind turbine tower, comprising:

[0007] Determine the wire diameter and corrosion resistance time of the wire rope to be processed according to the working conditions of the wire rope;

[0008] The weight of the zinc layer of the steel wire is calculated based on the determined steel wire diameter and corrosion resistance time;

[0009] The steel wire is processed by taking the determined steel wire diameter and the calculated steel wire zinc layer weight as processing parameters.

[0010] Furthermore, the diameter of the wire rope and the diameter of the steel wire are determined according to the working condition requirements of the wire rope.

[0011] Furthermore, the corrosion resistance time is determined according to the application environment of the steel wire rope.

[0012] Furthermore, the corrosion resistance time is the time during which no red rust appears on the steel wire rope when subjected to a neutral salt spray test.

[0013] Furthermore, the weight of the zinc layer of the steel wire is equal to the product of the sum of the corrosion resistance time of the steel wire rope and the first parameter and the diameter of the steel wire, divided by the ratio of the second parameter.

[0014] Furthermore, the corrosion resistance time of the steel wire rope is equal to the product of the corrosion resistance time of the steel wire rope actually processed and the adjustment parameter.

[0015] Furthermore, when the determined wire rope diameter is equal to the actual processed wire rope diameter, the adjustment parameter is 1; when the actual processed wire rope diameter changes, the corrosion resistance of the wire rope remains unchanged by adjusting the adjustment parameter.

[0016] Furthermore, the first parameter and the second parameter are obtained by fitting test data.

[0017] Furthermore, during the processing of the steel wire rope, the overall oil content of the steel wire rope is controlled not to exceed a threshold value.

[0018] In order to achieve the above-mentioned purpose, in a second aspect, the present invention also provides a steel wire for a steel wire rope for a wind turbine tower, which adopts the following technical solution:

[0019] A steel wire for a steel wire rope for a wind turbine tower, wherein the steel wire rope is processed by the processing method for the steel wire rope for a wind turbine tower as described in the first aspect.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] In the present invention, firstly, the steel wire diameter and corrosion resistance time of the steel wire rope to be processed are determined according to the use condition requirements, so as to ensure the corrosion resistance and strength requirements of the processed steel wire rope; then, according to the determined steel wire diameter and corrosion resistance time, the weight of the zinc layer of the steel wire is calculated, and the determined steel wire diameter and the calculated steel wire zinc layer weight are used as processing parameters to carry out the processing and production of large quantities of steel wires, without the need for neutral salt spray test and mechanical test, thereby greatly reducing the production cost and production cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings in the specification that constitute a part of this embodiment are used to provide a further understanding of this embodiment. The schematic embodiments of this embodiment and their descriptions are used to explain this embodiment and do not constitute improper limitations on this embodiment.

[0023] Figure 1 This is a flow chart of Example 1 of the present invention. DETAILED DESCRIPTION

[0024] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0025] It should be noted that the following detailed descriptions are exemplary and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meanings as those commonly understood by those skilled in the art to which the present application belongs.

[0026] Embodiment 1:

[0027] In order to meet the corrosion resistance requirements of steel wire ropes for wind turbine towers, it is necessary to use standard methods to conduct a 10-30 day neutral salt spray test on the steel wire ropes, and then observe whether red rust appears on the surface of the steel wire ropes to determine the corrosion resistance. This method has a long cycle, and once red rust appears within the prescribed test cycle, it means that the performance of the early small batch products does not meet the standards. At this time, the steel wire processing parameters need to be readjusted, which brings great waste to the company and increases the production cycle. To address this problem, if Figure 1 As shown, this embodiment provides a method for processing steel wire for a wind turbine tower, comprising:

[0028] Determine the wire diameter and corrosion resistance time of the wire rope to be processed according to the requirements of the wire rope use conditions;

[0029] The weight of the zinc layer of the steel wire is calculated based on the determined steel wire diameter and corrosion resistance time;

[0030] The steel wire is processed by taking the determined steel wire diameter and the calculated steel wire zinc layer weight as processing parameters.

[0031] Specifically, first, according to the working conditions of the steel wire rope, the steel wire diameter and corrosion resistance time of the steel wire rope to be processed are determined, thereby ensuring the corrosion resistance and strength requirements of the processed steel wire rope; then, according to the determined steel wire diameter and corrosion resistance time, the weight of the zinc layer of the steel wire is calculated, and the determined steel wire diameter and the calculated steel wire zinc layer weight are used as processing parameters to carry out large-scale processing and production of steel wires, without the need for neutral salt spray tests and mechanical tests, thereby greatly reducing production costs and production cycles.

[0032] Optionally, the diameter of the wire rope is determined according to the load-bearing requirements of the wire rope; for example, the load and safety factor of the application are first determined, the force that the wire rope must withstand is determined according to the load and safety factor, and then the diameter of the wire rope is determined, which can be determined by mathematical calculation or simulation technology. In the traditional way, in order to meet the breaking tension requirements of the wire rope, a standard strength grade steel wire is directly used, or a higher strength steel wire is used based on experience, and then only the weight of the zinc layer of the steel wire is adjusted and confirmed. Although this method simplifies the production process and shortens the processing cycle, if the strength level of the steel wire is much greater than the actual application load requirements, it will cause a waste of steel wire raw materials and processing costs; in this application, when determining the steel wire processing parameters, the parameter of determining the strength level of the steel wire according to the breaking tension requirements of the wire rope under the use conditions is added. On the basis of ensuring the load requirements, the waste caused by the excessively high strength level of the steel wire is avoided.

[0033] The corrosion resistance time is determined according to the use environment of the steel wire rope for the wind turbine tower. The corrosion resistance time is the time when no red rust appears in the steel wire rope during the neutral salt spray test. Optionally, when determining the corrosion resistance time, it is necessary to consider the dryness and humidity of the air in the use environment and adjust it within the requirements of the neutral salt spray test of 10 to 30 days. When the humidity in the use environment is high, the corrosion resistance time will be increased, and when the humidity in the use environment is low, the corrosion resistance time will be reduced.

[0034] The weight of the zinc layer of the steel wire is equal to the product of the corrosion resistance time of the steel wire rope and the first parameter and the diameter of the steel wire, and then divided by the ratio of the second parameter. Specifically, the corrosion resistance time determined by the neutral salt spray test time is:

[0035]

[0036] For example, the corrosion resistance requirement for the 6×19W-WSC-6.0mm steel wire rope used in wind turbine towers is: no red rust will appear within 480 hours of neutral salt spray test.

[0037] Where: Y is the neutral salt spray test time, h; M is the weight of the zinc layer of the steel wire, g / m 2 ; D is the wire diameter, mm; a is the first parameter, which can be set to 69.3; b is the second parameter, which can be set to 5.4; the first parameter and the second parameter can be obtained by fitting after acquiring a large amount of neutral salt spray test data.

[0038] By changing the above formula, we can get:

[0039] M=(Y+a)×D / b

[0040] For example, the outer wire diameter of the wire rope is 0.43mm or 0.31mm. According to the above formula, the neutral salt spray test time of the wire rope should be no less than 480 hours, and the minimum zinc layer of the 0.43mm steel wire in the debonded wire performance of the wire rope is 44g / m 2 , the minimum zinc layer weight of 0.31mm steel wire is 32g / m 2 .

[0041] In other usage scenarios, such as when using steel wire ropes to hoist wind turbine towers, the diameter of the steel wire ropes may be adjusted according to the load conditions due to changes in the weight of the wind turbine tower or adjustments to other stress conditions. At this time, in order to ensure that the weight of the zinc layer of the steel wire remains unchanged as much as possible, in other embodiments, the corrosion resistance time is set to the product of the corrosion resistance time of the steel wire obtained by actual processing and the adjustment parameter. By adjusting the adjustment parameter, the steel wire changes within the neutral salt spray test requirements within the range of 10 to 30 days. At this time, on the basis of meeting the corrosion resistance and load bearing requirements of the steel wire, the adjustment of the weight parameter of the zinc layer of the steel wire is avoided, the adjustment of the processing parameters is minimized, and the processing cycle time is guaranteed. Specifically:

[0042] M=(βY1+a)×D / b

[0043] Among them, β is an adjustment parameter. When the determined wire rope diameter is equal to the actual processed wire rope diameter, the adjustment parameter β is 1; when the actual processed wire rope diameter changes, the weight of the zinc layer of the steel wire remains unchanged by adjusting the adjustment parameter; Y1 is the corrosion resistance time of the actual processed wire rope. The corrosion resistance of the wire rope calculated by the method in this embodiment should be controlled so that the overall oil content of the wire rope does not exceed the threshold value of 1% during the production process.

[0044] By processing steel wires using the steel wire rope processing method in this embodiment and verifying the obtained steel wire ropes through a neutral salt spray test, the corrosion resistance of the product can be achieved by passing the neutral salt spray test inspection requirements in one go, which not only ensures product performance, reduces the defective rate of products, and shortens the production cycle, but also has good guiding significance for product design and processing.

[0045] Embodiment 2:

[0046] This embodiment provides a steel wire for a steel wire rope for a wind turbine tower. The steel wire is processed using the method for processing a steel wire for a steel wire rope for a wind turbine tower as described in Embodiment 1.

[0047] The above description is only a preferred embodiment of the present embodiment and is not intended to limit the present embodiment. For those skilled in the art, the present embodiment may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present embodiment shall be included in the protection scope of the present embodiment.

Claims

1. A method for processing steel wire rope for wind turbine tower, characterized in that: include: According to the working conditions of the steel wire rope for wind turbine tower, determine the steel wire diameter and corrosion resistance time of the steel wire rope to be processed; The weight of the zinc layer of the steel wire is calculated based on the determined steel wire diameter and corrosion resistance time; The steel wire is processed by taking the determined steel wire diameter and the calculated steel wire zinc layer weight as processing parameters; The diameter of the steel wire rope is determined according to the use load and safety factor of the steel wire rope for the wind turbine tower, and the corrosion resistance time is determined according to the use environment of the steel wire rope for the wind turbine tower; The corrosion resistance time is the time when the steel wire rope does not show red rust when undergoing a neutral salt spray test; The weight of the zinc layer of the steel wire is equal to the ratio of the sum of the corrosion resistance time of the steel wire rope and the first parameter to the diameter of the steel wire, divided by the second parameter; Specifically, ; Y is the neutral salt spray test time, h; M is the weight of the zinc layer of the steel wire, g / m 2 ; D is the wire diameter, mm; a is the first parameter, set to 69.3; b is the second parameter, set to 5.

4.

2. The method for processing a steel wire rope for a wind turbine tower as claimed in claim 1, characterized in that: The corrosion resistance time is equal to the product of the corrosion resistance time of the steel wire rope actually processed and the adjustment parameters.

3. The method for processing a steel wire rope for a wind turbine tower as claimed in claim 2, characterized in that: When the determined wire rope diameter is equal to the actual processed wire rope diameter, the adjustment parameter is 1; when the actual processed wire rope diameter changes, the weight of the zinc layer of the steel wire remains unchanged by adjusting the adjustment parameter.

4. The method for processing a steel wire rope for a wind turbine tower as claimed in claim 1, characterized in that: The first parameter and the second parameter are obtained by fitting the test data.

5. The method for processing a steel wire rope for a wind turbine tower as claimed in claim 1, characterized in that: During the wire rope processing, the overall oil content of the wire rope is controlled not to exceed the threshold.

6. A steel wire for a steel wire rope for a wind turbine tower, characterized in that: The steel wire is processed by the method for processing steel wire rope for wind turbine tower as described in any one of claims 1-5.

Images