Ropes and their manufacturing methods

Abstract

The rope consists of a core rope and multiple steel strands. The core rope is formed by twisting the multiple core rope strands together. Each core rope strand has multiple first filaments made of synthetic fibers and multiple second filaments made of synthetic fibers. The diameter of each second filament is smaller than the diameter of each first filament. The outer periphery of each first filament is surrounded by multiple second filaments.

Description

Technical Field

[0001] This disclosure relates to ropes and methods of manufacturing them. Background Technology

[0002] In conventional cables, multiple side strands are twisted around the outer periphery of the core rope. The core rope is constructed by twisting multiple core rope strands together. Each core rope strand has multiple yarns. Each yarn is constructed by blending monofilaments and multifilaments (see, for example, Patent Document 1).

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2013-170322 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In conventional cables as described above, there are many gaps between monofilaments and between multifilaments. Therefore, when the core rope is subjected to compressive forces from multiple side strands, each core strand undergoes elastic or plastic deformation, causing the core rope diameter to shrink. Consequently, it is impossible to sufficiently reduce the elastic elongation and annual elongation of the cable.

[0008] This disclosure was made to solve the aforementioned problems, and its purpose is to provide a rope and a method for manufacturing the same, which can reduce the gap within the core rope and suppress unnecessary elongation.

[0009] Methods for solving problems

[0010] The rope disclosed herein comprises: a core rope; and a plurality of steel strands twisted around the periphery of the core rope. The core rope is formed by twisting the plurality of core rope strands together. Each core rope strand has a plurality of first filaments made of synthetic fibers and a plurality of second filaments made of synthetic fibers. The diameter of each second filament is smaller than the diameter of each first filament, and the periphery of each first filament is surrounded by the plurality of second filaments.

[0011] In addition, the rope manufacturing method disclosed herein includes the following steps: twisting multiple second filaments of synthetic fiber with a diameter smaller than the first filament around the outer periphery of a first filament of synthetic fiber to produce small rope strands; twisting the multiple small rope strands together to produce core rope strands; twisting the multiple core rope strands together to produce a core rope; and twisting multiple steel rope strands around the outer periphery of the core rope.

[0012] Invention Effects

[0013] The rope and its manufacturing method disclosed herein can reduce the gap within the core rope and suppress unnecessary elongation. Attached Figure Description

[0014] Figure 1 This is a side view of the elevator according to embodiment 1.

[0015] Figure 2 yes Figure 1 A cross-sectional view of the main rope.

[0016] Figure 3 It is an enlarged representation Figure 2 A cross-sectional view of the core strand of the rope.

[0017] Figure 4 It means Figure 3 A cross-sectional view of the small rope strands in their state immediately after manufacturing.

[0018] Figure 5 It is an enlarged representation Figure 3 A cross-sectional view of a portion of the core rope strand.

[0019] Figure 6 This is an enlarged cross-sectional view showing a portion of the core rope strand of the first comparative example.

[0020] Figure 7 This is an enlarged cross-sectional view showing a portion of the core rope strand of the second comparative example.

[0021] Figure 8 This is an enlarged cross-sectional view showing a portion of the core rope strand of the third comparative example.

[0022] Figure 9 This is a cross-sectional view showing a first variation of the main rope in Embodiment 1.

[0023] Figure 10 This is a cross-sectional view showing a second variation of the main rope in Embodiment 1.

[0024] Figure 11 This is a cross-sectional view of the main rope in Embodiment 2.

[0025] Figure 12 This is a cross-sectional view of the main rope in embodiment 3. Detailed Implementation

[0026] The embodiments will now be described with reference to the accompanying drawings.

[0027] Implementation method 1.

[0028] Figure 1 This is a side view showing the elevator according to Embodiment 1. Figure 1 In the hoistway 1, a machine room 2 is installed above it. A traction machine 3 and a deflector wheel 6 are installed in the machine room 2.

[0029] The traction machine 3 has a traction machine body 4 and a drive sheave 5. The traction machine body 4 has a traction machine motor (not shown) and a traction mechanism brake (not shown). The traction machine motor rotates the drive sheave 5. The traction mechanism brake keeps the drive sheave 5 stationary. In addition, the traction mechanism brakes the rotation of the drive sheave 5.

[0030] Multiple main ropes 7 are wound on the drive sheave 5 and the deflector sheave 6. The multiple main ropes 7 are elevator ropes.

[0031] The car 8 and counterweight 9 are suspended within the hoistway 1 by multiple main ropes 7. Furthermore, the car 8 and counterweight 9 rise and fall within the hoistway 1 by rotating the drive sheave 5.

[0032] A pair of car guide rails 10 and a pair of counterweight guide rails 11 are installed inside the hoistway 1. Figure 1 The image shows only one side of the car guide rail 10 and one side of the counterweight guide rail 11.

[0033] A pair of car guide rails 10 guide the lifting and lowering of the car 8. A pair of counterweight guide rails 11 guide the lifting and lowering of the counterweight 9.

[0034] The car 8 has a car frame 12 and a car compartment 13. Multiple main ropes 7 are connected to the car frame 12. The car compartment 13 is supported by the car frame 12.

[0035] Figure 2 yes Figure 1 A cross-sectional view of the main rope 7, showing a section perpendicular to the length direction of the main rope 7. The main rope 7 in Embodiment 1 is an 8×S(19) type rope according to JIS G 3525.

[0036] The main rope 7 has a core rope 21 and multiple steel strands 22. In this example, eight steel strands 22 are twisted around the outer periphery of the core rope 21.

[0037] The core rope 21 is positioned at the center of the cross-section of the main rope 7 perpendicular to its length. Furthermore, the core rope 21 is constructed by twisting multiple core rope strands 23 together. In this example, three core rope strands 23 are used. That is, the core rope 21 of Embodiment 1 is a so-called three-strand rope. Lubricating grease or oil can also be incorporated into the core rope 21.

[0038] Each steel rope strand 22 has multiple steel single wires. The multiple steel single wires include a center single wire 24, multiple intermediate single wires 25, and multiple outer single wires 26.

[0039] The center single line 24 is positioned at the center of the cross-section of the steel rope strand 22, perpendicular to its length. Multiple intermediate single lines 25 are twisted around the center single line 24. In this example, nine intermediate single lines 25 are used.

[0040] Multiple outer single strands 26 are twisted around the periphery of an intermediate layer composed of multiple middle single strands 25. In this example, nine outer single strands 26 are used. That is, in each steel rope strand 22, the number of middle single strands 25 is the same as the number of outer single strands 26.

[0041] The diameter of each outermost single line 26 is smaller than the diameter of the center single line 24. The diameter of each middle single line 25 is smaller than the diameter of each outermost single line 26.

[0042] Furthermore, when the loads of the car 8 and the counterweight 9 are actually applied to the main rope 7, each steel rope strand 22 is pressed against the outer periphery of the core rope 21.

[0043] Figure 3 It is an enlarged representation Figure 2 A cross-sectional view of the core rope strand 23, showing the section of the core rope strand 23 perpendicular to the length direction. Each core rope strand 23 has multiple first filaments 31 and multiple second filaments 32 made of synthetic fibers.

[0044] The diameter of each second filament 32 is smaller than the diameter of each first filament 31. Conversely, the diameter of each first filament 31 is larger than the diameter of each second filament 32. When the diameter of the first filament 31 is set as d1 and the diameter of the second filament 32 is set as d2, d1 / d2 is preferably 2 or more. Furthermore, d1 / d2 is more preferably 3 or more and 5 or less.

[0045] Each first filament 31 is surrounded by multiple second filaments 32. Thus, multiple second filaments 32 are sandwiched between adjacent first filaments 31.

[0046] First synthetic fibers are used as the material for each of the first filaments 31. Second synthetic fibers are used as the material for each of the second filaments 32.

[0047] The second synthetic fiber is preferably selected considering its resistance to abrasion from contact and friction with the steel rope strands 22. Therefore, polyester fiber, especially polyethylene terephthalate (PET) fiber, is preferred as the second synthetic fiber.

[0048] The first synthetic fiber can be made of the same material as the second synthetic fiber, or it can be made of a different material.

[0049] For example, polyethylene terephthalate filaments with a diameter of 100 μm can be used as the first filament 31, and polyethylene terephthalate filaments with a diameter of 30 μm can be used as the second filament 32. In this case, d1 / d2 is approximately 3.3.

[0050] When d1 / d2 is less than 2, multiple second filaments 32 may not be able to fully enter between adjacent first filaments 31. However, d1 / d2 is not necessarily limited to 2 or more.

[0051] Each core rope strand 23 is formed by twisting multiple small rope strands 27 together. In this example, 7 small rope strands 27 are used.

[0052] Each strand 27 has a first filament 31 and multiple second filaments 32. In each strand 27, the multiple second filaments 32 are twisted around the outer periphery of the first filament 31.

[0053] Next, the manufacturing method of the main rope 7 will be described. The manufacturing method of the main rope 7 in Embodiment 1 includes a small rope strand manufacturing process, a core rope strand manufacturing process, a core rope manufacturing process, and a process of twisting multiple steel rope strands 22 around the outer periphery of the core rope 21.

[0054] The process of manufacturing small rope strands is to twist multiple second fibers 32 around the outer periphery of the first fiber 31 to create small rope strands 27.

[0055] Figure 4 It means Figure 3 A cross-sectional view of the state of the small rope strand 27 immediately after manufacturing. In the newly manufactured small rope strand 27, multiple second filaments 32 are evenly twisted around the outer periphery of the first filament 31.

[0056] The core rope strand manufacturing process is the process of twisting multiple small rope strands 27 together to create the core rope strand 23.

[0057] The core rope manufacturing process is the process of twisting multiple core rope strands 23 together to manufacture the core rope 21.

[0058] After the core rope 21 is manufactured, multiple steel strands 22 are twisted around the outer periphery of the core rope 21 to manufacture the main rope 7.

[0059] Figure 5 It is an enlarged representation Figure 3 A cross-sectional view of a portion of the core rope strand 23. By twisting multiple second fibers 32 around the outer periphery of each first fiber 31, even if multiple small rope strands 27 are twisted together, the multiple second fibers 32 are not easily unraveled. Therefore, it is possible to more reliably achieve a state in which each first fiber 31 is surrounded by multiple second fibers 32.

[0060] Figure 6 This is an enlarged cross-sectional view showing a portion of the core rope strand of the first comparative example. The core rope strand of the first comparative example consists only of multiple first filaments 31. Furthermore, Figure 7 This is an enlarged cross-sectional view showing a portion of the core rope strand of the second comparative example. The core rope strand of the second comparative example consists only of multiple second filaments 32.

[0061] In the core strands of the first comparative example, the number of gaps is small, but the size of each gap is large. On the other hand, in the core strands of the second comparative example, the size of each gap is small, but the number of gaps is large. Thus, when all the filaments contained in each core strand have the same diameter, the total number of gaps remains unchanged regardless of the diameter.

[0062] In contrast, Figure 5 In the core rope strand 23 of Embodiment 1 shown, the diameter of each second filament 32 is smaller than the diameter of each first filament 31. Furthermore, multiple second filaments 32 are inserted between adjacent first filaments 31. Therefore, the gaps within the core rope strand 23 can be significantly reduced.

[0063] Figure 8 This is an enlarged cross-sectional view showing a portion of the core rope strand of the third comparative example. The core rope strand of the third comparative example has multiple first yarns and multiple second yarns. Each first yarn is formed by bundling multiple first filaments 31. Each second yarn is formed by bundling multiple second filaments 32.

[0064] In the third comparative example, multiple second filaments 32 do not enter between adjacent first filaments 31. Therefore, the total amount of gaps is the same as in the first and second comparative examples.

[0065] Thus, in the main rope 7 of Embodiment 1, the diameter of each second filament 32 is smaller than the diameter of each first filament 31. Moreover, the outer periphery of each first filament 31 is surrounded by multiple second filaments 32.

[0066] In addition, in the strand manufacturing process of the main rope 7 manufacturing method in Embodiment 1, multiple second fibers 32 are twisted around the outer periphery of the first fiber 31 to manufacture strands 27.

[0067] This reduces the gaps within the core rope 21, preventing a decrease in its diameter when subjected to compressive forces from the multiple steel strands 22. Consequently, unnecessary elongation of the main rope 7 can be suppressed. Furthermore, this extends the lifespan of the main rope 7.

[0068] In addition, in elevators with long lifting distances, it can suppress the vibration of the car 8 when users ride in and out of the car 8.

[0069] Furthermore, multiple second filaments 32 are twisted around the outer periphery of each first filament 31. Therefore, during the manufacturing of the core rope strand 23, the separation of the multiple second filaments 32 from the outer periphery of each first filament 31 can be prevented. As a result, the gaps within the core rope 21 can be reduced more reliably.

[0070] Furthermore, multiple second filaments 32 are sandwiched between adjacent first filaments 31. Therefore, adjacent first filaments 31 do not directly contact each other. As a result, the gaps within the core rope 21 can be reduced more reliably.

[0071] Figure 9 This is a cross-sectional view showing a first variation of the main rope 7 in Embodiment 1. In this first variation, by compressing each steel rope strand 22 from the radially outer side, the cross-sectional shape of each steel rope strand 22 perpendicular to the length direction becomes circular. That is, the cross-sectional shape of each steel rope strand 22 is irregularized.

[0072] The same effect as in embodiment 1 can be achieved through the main rope 7 of this first variant example.

[0073] Furthermore, the number of core rope strands 23 included in the core rope 21 is not limited to three.

[0074] In addition, the number of steel rope strands 22 is not limited to 8.

[0075] Figure 10 This is a cross-sectional view showing a second variation of the main rope 7 in Embodiment 1. In this second variation, 12 steel strands 22 are used. Furthermore, the cross-sectional shape of each steel strand 22 is modified in the same way as in the first variation.

[0076] The same effect as in embodiment 1 can be achieved through the main rope 7 of this second variation.

[0077] Implementation method 2.

[0078] then, Figure 11 This is a cross-sectional view of the main rope 7 in Embodiment 2, showing the section of the main rope 7 perpendicular to its length direction. In addition to having multiple core rope strands 23, the core rope 21 in Embodiment 2 also has a central rope strand 33 and multiple peripheral rope strands 34.

[0079] The center strand 33 is positioned at the center of the core rope 21 in a section perpendicular to the length direction.

[0080] Each outer peripheral strand 34 is arranged around the periphery of the core rope 21 between adjacent core rope strands 23. The number of outer peripheral strands 34 is the same as the number of core rope strands 23. In embodiment 2, three outer peripheral strands 34 are used for the three core rope strands 23.

[0081] As the center strand 33, a twisted yarn made of synthetic fibers can be used. For example, as the center strand 33, it is possible to use a twisted yarn with a diameter that is appropriately adjusted to... Figure 4 The small strands 27 shown are strands with the same cross-sectional structure. Each outer strand 34 can be the same as the central strand 33.

[0082] The other structures in Implementation 2 are the same as those in Implementation 1.

[0083] In this main rope 7, the gap at the center of the core rope 21 is filled by the central strand 33. Therefore, the gap within the core rope 21 can be further reduced, and unnecessary elongation of the main rope 7 can be more reliably suppressed.

[0084] Furthermore, the three gaps between adjacent core rope strands 23 on the outer periphery of the core rope 21 are filled by the three outer periphery strands 34. Therefore, the gaps within the core rope 21 can be further reduced, and unnecessary elongation of the main rope 7 can be more reliably suppressed.

[0085] Alternatively, either the central strand 33 or the multiple peripheral strands 34 can be omitted.

[0086] Alternatively, it can also be done in Figure 9 In the first variant shown, the main rope 7 is provided with at least one of a central rope strand 33 and multiple peripheral rope strands 34.

[0087] Alternatively, it can also be done in Figure 10 In the second variation shown, the main rope 7 is provided with at least one of a central rope strand 33 and multiple peripheral rope strands 34.

[0088] Implementation method 3.

[0089] then, Figure 12 This is a cross-sectional view of the main rope 7 in Embodiment 3, showing a section of the main rope 7 perpendicular to its length direction. In addition to the core rope 21 and multiple steel strands 22, the main rope 7 in Embodiment 3 also has a core rope sheath 35. The core rope sheath 35 covers the outer periphery of the core rope 21. That is, the core rope sheath 35 is located between the core rope 21 and the multiple steel strands 22.

[0090] Resin or rubber can be used as the material for the core cord coating 35. Specifically, materials such as polyethylene, polypropylene, polyvinyl chloride, polyamide, or polyurethane elastomer can be used as the material for the core cord coating 35.

[0091] Furthermore, the core rope coating 35 is applied to the outer periphery of the core rope 21 through the same manufacturing process as that used for applying coatings to cables. That is, the core rope coating 35 is applied to the outer periphery of the core rope 21 by extrusion coating, in which the core rope 21 passes through the center.

[0092] The other structures in Implementation 3 are the same as those in Implementation 1.

[0093] In this main rope 7, the three gaps between adjacent core rope strands 23 on the outer periphery of the core rope 21 are filled by the core rope cladding 35. Therefore, the gaps within the core rope 21 can be further reduced, and unnecessary elongation of the main rope 7 can be more reliably suppressed.

[0094] In addition, since the core rope 21 does not come into direct contact with the multiple steel strands 22, wear and damage to the core rope 21 can be suppressed.

[0095] Alternatively, at least one of the central strand 33 and multiple peripheral strands 34 shown in Embodiment 2 can be provided in the main rope 7 of Embodiment 3.

[0096] Alternatively, it can also be done in Figure 9 In the first modified example shown, the main rope 7 is provided with a core rope cover 35. Alternatively, in the first modified example, the main rope 7 may be provided with at least one of the core rope cover 35, the central strand 33, and the plurality of peripheral strands 34.

[0097] Alternatively, it can also be done in Figure 10 In the second modified example shown, the main rope 7 is provided with a core rope cover 35. Alternatively, in the second modified example, the main rope 7 may be provided with at least one of the core rope cover 35, the central strand 33, and a plurality of peripheral strands 34.

[0098] Furthermore, in embodiments 1 to 3, the overall layout of the elevator is not limited to... Figure 1 The layout. For example, the rope winding method can also be a 2:1 rope winding method.

[0099] In addition, elevators can also be machine-room-less elevators, double-decker elevators, and single-shaft multi-car elevators. A single-shaft multi-car elevator is one in which the upper car and the lower car, located directly below the upper car, move independently up and down in a common shaft.

[0100] Alternatively, the rope can be an elevator rope other than the main rope 7, such as a compensation rope or a speed limiting rope.

[0101] In addition, ropes are not limited to elevator ropes; they can also be ropes used for other purposes, such as lifting ropes for lifting devices.

[0102] Label Explanation

[0103] 7: Main rope (rope), 21: Core rope, 22: Steel rope strand, 23: Core rope strand, 27: Small rope strand, 31: First fiber, 32: Second fiber, 33: Center rope strand, 34: Outer rope strand, 35: Core rope covering.

Claims

1. A rope comprising: Core rope; and Multiple steel strands are twisted around the outer periphery of the core rope. The core rope is formed by twisting together multiple core rope strands. Each core rope strand is formed by twisting together multiple small rope strands. Each of the aforementioned small rope strands has a single first filament made of synthetic fiber and multiple second filaments made of synthetic fiber. The diameter of each second filament is smaller than the diameter of each first filament. The outer periphery of each of the first fibers is surrounded by the plurality of second fibers.

2. The rope according to claim 1, wherein, The plurality of second fibers are twisted around the periphery of each of the first fibers.

3. The rope according to claim 1, wherein, Each of the second filaments is made of polyester fiber.

4. The rope according to claim 2, wherein, Each of the second filaments is made of polyester fiber.

5. The rope according to any one of claims 1 to 4, wherein, The plurality of second fibers are sandwiched between adjacent first fibers.

6. The rope according to any one of claims 1 to 4, wherein, The core rope has a central strand disposed at the center of the core rope.

7. The rope according to claim 5, wherein, The core rope has a central strand disposed at the center of the core rope.

8. The rope according to any one of claims 1 to 4 and claim 7, wherein, The core rope has a plurality of peripheral strands arranged on the outer periphery of the core rope between adjacent core rope strands.

9. The rope according to claim 5, wherein, The core rope has a plurality of peripheral strands arranged on the outer periphery of the core rope between adjacent core rope strands.

10. The rope according to claim 6, wherein, The core rope has a plurality of peripheral strands arranged on the outer periphery of the core rope between adjacent core rope strands.

11. The rope according to any one of claims 1 to 4, 7, and 9 to 10, wherein, The rope also has a core rope covering layer that covers the outer periphery of the core rope.

12. The rope according to claim 5, wherein, The rope also has a core rope covering layer that covers the outer periphery of the core rope.

13. The rope according to claim 6, wherein, The rope also has a core rope covering layer that covers the outer periphery of the core rope.

14. The rope according to claim 8, wherein, The rope also has a core rope covering layer that covers the outer periphery of the core rope.

15. A method for manufacturing a rope, comprising the following steps: Small rope strands are made by twisting multiple second filaments made of synthetic fibers with a smaller diameter than the first filament around the outer periphery of a single synthetic fiber first filament. The core rope strand is made by twisting multiple of the small rope strands together. A core rope is manufactured by twisting multiple strands of the aforementioned core rope together; and Multiple steel strands are twisted around the outer periphery of the core rope.

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