A method for making a prefabricated broken wire rope sample of a steel wire rope

Abstract

The invention discloses a method for making a prefabricated broken wire rope sample of a steel wire rope. The method comprises the following steps: selecting a steel wire rope structure and specification according to the requirements of the broken wire rope sample; selecting a broken wire rope sample type, which includes: type A, type B, and type C; calculating the sum of the cross-sectional areas of all steel wires in the steel wire rope; calculating the diameters of steel wires that need to be replaced in type A and type B according to a specified area loss, and calculating the diameter of steel wires that need to be increased in type C according to a specified area increase; producing steel wires of corresponding diameter specifications for backup; for type A and type B rope samples, firstly extracting the replaced steel wire from the rope sample, and then adding the spare steel wire; for type C rope sample, straightening the steel wire rope along the length direction, disassembling the outer strands, adding the spare steel wire to the steel core of the steel wire rope, and fixing the spare steel wire between the gaps of the steel core; obtaining a prepared rope sample, and cutting and removing the replaced or added steel wire according to the requirements of a specific broken wire spacing; firmly fixing the steel wire at the cutoff position, and marking the defective position.

Description

Technical Field

[0001] The invention belongs to the technical field of steel wire rope manufacturing, and in particular relates to a method for manufacturing a prefabricated broken wire rope sample of a steel wire rope. Background Art

[0002] Wire rope is a spiral wire bundle twisted together according to certain rules with steel wires that meet the requirements of mechanical properties and geometric dimensions. In material handling machinery, it is used for lifting, pulling, tightening and carrying. Wire rope has high strength, light weight and reliable operation. If wires are broken in the wire rope due to manufacturing, transportation, and use, it will pose a major hidden danger to the safety of the wire rope and the safety of the equipment used to install the wire rope. Therefore, it is extremely important to study wire breakage in wire rope.

[0003] Broken wire is the most common quality defect in the use of wire rope. Different standards have different scrap conditions for broken wire. How to determine the scrap base point of wire rope in practice has become a technical key. The main factor affecting the scrap base point of wire rope is the change in the effective metal cross-sectional area. In actual application, broken wire or wear directly affects the cross-sectional area of ​​wire rope. Therefore, the research on broken wire of wire rope has become a key technology in the industry. In the laboratory, it is necessary to prefabricate broken wire rope samples according to standard requirements, simulate actual industrial and mining for testing, and conduct theoretical analysis and actual production. It can be seen that it is necessary to develop a method for prefabricating broken wire rope samples of wire rope to provide a scientific basis for the laboratory. Summary of the invention

[0004] The present invention aims at the above-mentioned problems, makes up for the deficiencies of the prior art, and provides a method for producing prefabricated broken wire rope samples of steel wire rope; the method of the present invention can produce steel wire rope samples with broken wire defects that meet the standard requirements, thereby providing laboratories with broken wire rope samples that meet the standard requirements.

[0005] To achieve the above purpose, the present invention adopts the following technical solution.

[0006] The present invention provides a method for manufacturing a prefabricated broken wire rope sample of a steel wire rope, which specifically comprises the following steps:

[0007] Step 1: Select the wire rope structure and specifications according to the broken wire rope sample requirements;

[0008] Step 2: Select the type of broken wire rope sample according to the broken wire rope sample requirements. The broken wire rope sample types include: Class A, Class B, and Class C. Class A is the wire rope surface broken wire rope sample, Class B is the wire rope steel core broken wire rope sample, and Class C is the wire rope added broken wire rope sample;

[0009] Step 3, calculate the sum of the cross-sectional areas of all the steel wires in the steel wire rope, and select the type of broken wire rope sample according to step 2; calculate the steel wire diameters that need to be replaced for Class A and Class B according to the specified area loss, and calculate the steel wire diameter that needs to be increased for Class C according to the specified area increase;

[0010] Step 4, according to the steel wire diameter calculated in step 3, produce steel wire of corresponding diameter for standby;

[0011] Step 5, according to the calculated diameter in step 4, for broken wire rope samples of category A and category B, first extract the steel wire to be replaced from the rope sample, and then add the spare steel wire; for broken wire rope samples of category C, straighten the steel rope along the length direction, disassemble the outer strands, add the spare steel wire to the steel core of the steel rope, and fix the spare steel wire between the gaps of the steel core;

[0012] Step 6, prepare the rope sample according to step 5, and cut and remove the replaced or added steel wire according to the specific wire breaking spacing requirement;

[0013] Step 7. Fix the wire firmly at the cut point to prevent it from loosening and mark the defect.

[0014] Furthermore, in step 1, a steel wire rope with a 16×19S-IWRC structure is selected, and the diameter of the steel wire rope is 24 mm.

[0015] Furthermore, in step 3, the diameter of the steel wire in the outer layer of the outer strand of the steel wire rope that needs to be replaced for class A is calculated, the diameter of the steel wire in the outer layer of the outer strand of the steel core that needs to be replaced for class B is calculated, and the diameter of the steel wire that needs to be increased between the gaps in the steel core for class C is calculated.

[0016] Furthermore, in step 3, the wire diameter is calculated from the area by using the relationship between the area and radius of the circle.

[0017] Furthermore, in step 5, spare steel wires are added to the steel core of the steel wire rope, and glue is used to fix the spare steel wires between the gaps of the steel core.

[0018] Furthermore, in step 6, the specific broken wire spacing is 760 mm.

[0019] The beneficial effects of the present invention are as follows: the method for making prefabricated broken wire rope samples of steel wire ropes provided by the present invention can complete the production of broken wire rope samples of steel wire ropes with specific broken wire spacing requirements as required, making the broken wire rope sample production method more direct and simple. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic diagram of the length and position of the broken wire is made for the present invention. DETAILED DESCRIPTION

[0021] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods. It should be understood that the specific implementation methods described herein are only used to explain the present invention and are not used to limit the present invention.

[0022] Example 1

[0023] A method for making a prefabricated broken wire rope sample of a steel wire rope provided in an embodiment of the present invention specifically comprises the following steps:

[0024] Step 1: Select the wire rope structure and specifications according to the broken wire rope sample requirements;

[0025] Step 2: Select the type of broken wire rope sample according to the broken wire rope sample requirements. The broken wire rope sample types include: Class A, Class B, and Class C. Class A is the wire rope surface broken wire rope sample, Class B is the wire rope steel core broken wire rope sample, and Class C is the wire rope added broken wire rope sample;

[0026] Step 3, calculate the sum of the cross-sectional areas of all the steel wires in the steel wire rope, and select the type of broken wire rope sample according to step 2; calculate the diameters of each type of steel wire that needs to be replaced according to the specified area loss: Class A calculates the diameter of the steel wire in the outer layer of the outer strand of the steel rope that needs to be replaced, and Class B calculates the diameter of the steel wire in the outer layer of the outer strand of the steel core that needs to be replaced; calculate the diameter of the steel wire that needs to be increased according to the specified area increase: Class C calculates the diameter of the steel wire that needs to be increased between the gaps in the steel core; by using the relationship between the area and radius of a circle, the wire diameter is calculated from the area.

[0027] Step 4, according to the steel wire diameter calculated in step 3, produce steel wire of corresponding diameter for standby use.

[0028] Step 5. According to the calculated diameter in step 4, for broken wire rope samples of type A and type B, first pull out the steel wire to be replaced from the rope sample, and then add the spare steel wire; for broken wire rope samples of type C, straighten the steel rope along the length direction, disassemble the outer strands, add the spare steel wire to the steel core of the wire rope, and use glue to fix the spare steel wire between the gaps of the steel core.

[0029] Step 6, prepare the rope sample according to step 5, and cut and remove the replaced or added steel wires according to the specific broken wire spacing requirements.

[0030] Step 7. Fix the wire firmly at the cut point to prevent it from loosening and mark the defect.

[0031] Example 2

[0032] A method for making a prefabricated broken wire rope sample of a steel wire rope provided in an embodiment of the present invention specifically comprises the following steps:

[0033] Step 1, taking a 6×19S-IWRC steel wire rope as an example, the steel wire rope diameter specification is 24 mm, and rope samples are made for Class A, Class B, and Class C broken wire rope samples respectively.

[0034] Step 2, select the broken wire rope sample type: Type A is the wire rope surface broken wire rope sample, Type B is the wire rope steel core broken wire rope sample, Type C is the wire rope added broken wire rope sample;

[0035] Step 3, calculate the sum of the cross-sectional areas of all the wires in the wire rope, which is 282.14 mm 2 ;

[0036] Step 3.1, the specified area change is 0.5% of the sum of the cross-sectional areas of all wire ropes, and the loss area of ​​the broken wire rope sample of type A is 1.41mm 2 , calculated from the relationship between the area and radius of the circle, the diameter of the outer strand of steel wire that needs to be replaced is 1.34 mm;

[0037] Step 3.2, the specified area change is 0.1% of the sum of the cross-sectional areas of all wire ropes, and the loss area of ​​the broken wire rope sample of type B is 0.282mm 2 , calculated from the relationship between the area and radius of the circle, the diameter of the outer layer of the steel core strand that needs to be replaced is 0.60mm;

[0038] Step 3.3, the specified area change is 0.1% of the sum of the cross-sectional areas of all wire ropes, and the increased area of ​​the C-type broken wire rope sample is 1.41mm 2 , calculated from the relationship between the area and radius of the circle, the diameter of the steel wire to be added is 1.34mm;

[0039] Step 4: A type of broken wire rope sample produces a spare steel wire with a diameter of 1.34 mm, a type of broken wire rope sample produces a spare steel wire with a diameter of 0.60 mm, and a type of broken wire rope sample produces a spare steel wire with a diameter of 1.34 mm;

[0040] Step 5, replace the steel wire or add steel wire;

[0041] Step 5.1: For the broken wire rope sample of type A, pull out a steel wire from the outer layer of the outer strand of the steel wire rope and replace it with a spare 1.34 mm steel wire;

[0042] Step 5.2: For the broken wire rope of type B, pull out a steel wire from the outer layer of the steel core of the steel rope and replace it with a spare 0.60 mm steel wire;

[0043] Step 5.3, Class C broken wire rope sample: straighten the wire rope along the length direction, disassemble the outer strands, add spare 1.34mm steel wire to the steel core of the wire rope, and use glue to fix the spare steel wire between the gaps of the steel core.

[0044] Step 6, make 10 different lengths of broken wires, the specific lengths are: 1.5mm, 3mm, 6mm, 12mm, 25mm, 50mm, 100mm, 200mm, 400mm, 800mm; the length of the steel wire is calculated according to the straight line distance of the wire rope, the spacing between each broken wire is 760mm, and the position error should be ≤20mm, see Figure 1 As shown;

[0045] Step 7, straighten the wire rope along the length direction, and fix the wire at the cut point firmly to prevent it from loosening; at the defect, mark the wire rope according to the length of the defect.

[0046] It can be understood that the above specific description of the present invention is only used to illustrate the present invention and is not limited to the technical solutions described in the embodiments of the present invention. Those skilled in the art should understand that the present invention can still be modified or replaced by equivalents to achieve the same technical effects; as long as the use requirements are met, they are within the protection scope of the present invention.

Claims

1. A method for making a prefabricated broken wire rope sample of a steel wire rope, characterized in that: The specific steps include: Step 1: Select the wire rope structure and specifications according to the broken wire rope sample requirements; Step 2: Select the type of broken wire rope sample according to the broken wire rope sample requirements. The broken wire rope sample types include: Class A, Class B, and Class C. Class A is the wire rope surface broken wire rope sample, Class B is the wire rope steel core broken wire rope sample, and Class C is the wire rope added broken wire rope sample; Step 3, calculate the sum of the cross-sectional areas of all the steel wires in the steel wire rope, and select the type of broken wire rope sample according to step 2; calculate the steel wire diameters that need to be replaced for Class A and Class B according to the specified area loss, and calculate the steel wire diameter that needs to be increased for Class C according to the specified area increase; Step 4, according to the steel wire diameter calculated in step 3, produce steel wire of corresponding diameter for standby; Step 5, according to the calculated diameter in step 4, for broken wire rope samples of category A and category B, first extract the steel wire to be replaced from the rope sample, and then add the spare steel wire; for broken wire rope samples of category C, straighten the steel rope along the length direction, disassemble the outer strands, add the spare steel wire to the steel core of the steel rope, and fix the spare steel wire between the gaps of the steel core; Step 6, prepare the rope sample according to step 5, and cut and remove the replaced or added steel wire according to the specific wire breaking spacing requirement; Step 7. Fix the wire firmly at the cut point to prevent it from loosening and mark the defect.

2. A method for making a prefabricated broken wire rope sample of a steel wire rope according to claim 1, characterized in that: In the step 1, a steel wire rope of 16×19S-IWRC structure is selected, and the diameter of the steel wire rope is 24 mm.

3. The method for making a prefabricated broken wire rope sample of a steel wire rope according to claim 1, characterized in that: In step 3, the diameter of the steel wire in the outer layer of the outer strand of the steel wire rope that needs to be replaced for class A is calculated, the diameter of the steel wire in the outer layer of the outer strand of the steel core that needs to be replaced for class B is calculated, and the diameter of the steel wire that needs to be increased between the gaps in the steel core for class C is calculated.

4. The method for making a prefabricated broken wire rope sample of a steel wire rope according to claim 1, characterized in that: In step 3, the wire diameter is calculated from the area by using the relationship between the area and radius of a circle.

5. The method for making a prefabricated broken wire rope sample of a steel wire rope according to claim 1, characterized in that: In step 5, spare steel wires are added to the steel core of the steel wire rope, and glue is used to fix the spare steel wires between the gaps of the steel core.

6. The method for making a prefabricated broken wire rope sample of a steel wire rope according to claim 1, characterized in that: In step 6, the specific broken wire spacing is 760 mm.

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