A device and method for making small diameter steel wire strands

Abstract

The application discloses a small-diameter steel wire strand manufacturing device and method. The device comprises a wire releasing device for releasing steel wires, the wire releasing device having a fixed damping to make the released steel wires have a certain initial tension; a pair of steering devices oppositely arranged, the steel wires being reciprocally wound through the pair of steering devices; a traction device having a fixed load and being connected to and pulling the outer ends of the steel wires on the wire releasing device, the traction device pulling the steel wires to be reciprocally wound along the pair of steering devices at a rated tension until a required number of steel wires for a strand is formed; and a shaping device for shaping and compacting the multiple steel wires after winding to make the steel wires form a required shape and compacting force of the strand. The application solves the problem of manufacturing small-diameter steel wire strands of a main cable of a suspension bridge, and has the advantages of convenient installation and application, convenient operation, controllable quality, and no need of large mechanical equipment.

Description

Technical Field

[0001] This invention relates to the field of suspension bridge main cable strand fabrication technology. More specifically, this invention relates to a device and method for fabricating small-diameter steel wire strands. Background Technology

[0002] The main cable is a key component of a suspension bridge, and its performance is crucial to the bridge's load-bearing capacity and durability. The main cable is generally composed of numerous steel wires, and the interactions between these wires are complex. The lateral characteristics of the main cable cannot be simply obtained by superimposing the lateral characteristics of the steel wires. Therefore, scholars both domestically and internationally have conducted extensive theoretical analysis and experimental research on suspension bridge main cables.

[0003] Currently, in the scaling tests of main cables for suspension bridges, the number of strands or steel wire ropes are often reduced to simulate the main cable, which cannot accurately simulate the interaction between the steel wires. If the main cable steel wires are scaled down proportionally, the diameter of the main cable steel wires will be less than 1mm, and the steel wires are prone to twisting and knotting. In addition, conventional strand making equipment cannot be used, and there is currently no strand making device or method for steel wires with a diameter of less than 1mm.

[0004] In summary, this invention proposes a device and method for manufacturing small-diameter steel wire strands for main cables. Summary of the Invention

[0005] One objective of this invention is to provide a device and method for manufacturing main cable strands of small-diameter steel wires without relying on large equipment, which solves the problem of manufacturing small-diameter steel wire strands for main cables of suspension bridges. It has the advantages of convenient installation and application, easy operation, controllable quality, and no need for large mechanical equipment.

[0006] To address the aforementioned technical problems, this invention provides a small-diameter steel wire strand manufacturing device, comprising: a wire feeding device for feeding steel wires, the wire feeding device having fixed damping to ensure that the fed steel wires have a certain initial tension; a pair of turning devices arranged opposite to each other, through which the steel wires are reciprocated; a traction device having a fixed load and connected to and pulling the outer end of the steel wires on the wire feeding device, the traction device pulling the steel wires reciprocally along the pair of turning devices at a rated tension until the required number of steel wires for strand weaving is formed; and a shaping device for shaping and pressing the multiple steel wires after winding to form the required shape and pressing force for strand weaving.

[0007] Preferably, the wire feeding device includes a fixed block, a base plate and a rotating shaft rotatably mounted on the fixed block, a wire feeding disc sleeved on the rotating shaft, and a damper mounted on the fixed block. The central axes of the base plate and the rotating shaft coincide, the wire feeding disc rotates synchronously with the base plate and the rotating shaft, and the damper contacts the base plate to control the torque required when the base plate rotates, ensuring that the wire has initial tension when feeding.

[0008] Preferably, the steering device includes a column, a pulley bracket fixed to the outside of the column, and a pulley disposed on the pulley bracket. The steel wire is wound around the pulley and changes direction through the pulley. A pair of columns of a pair of steering devices are arranged opposite to each other, and a pair of pulleys on a pair of columns are located in the same horizontal plane.

[0009] Preferably, the traction device includes a force gauge and a traction device, and the steel wire is connected in series with the force gauge and the traction device. The force gauge is used to ensure that the tension of the steel wire is constant during traction.

[0010] Preferably, it also includes a mid-span support, which includes a pair of fixed columns arranged opposite each other on both sides of the steel wire, a crossbeam connecting the pair of fixed columns into one piece, the pair of fixed columns being located at the center of a pair of steering devices, and each pair of fixed columns being provided with a scale to measure the sag of the steel wire mid-span, so as to ensure that the tension of the steel wire is consistent and accurate.

[0011] Preferably, the shaping device includes a pair of shaping clamps and multiple wrapping tapes. The pair of shaping clamps are positioned between a pair of turning devices to shape and tighten the steel wire. The shaping clamps include a pair of clamping plates and bolts that connect the pair of clamping plates into one piece. The center of the opposite surfaces of the pair of clamping plates is provided with a groove. After the pair of clamping plates are closed and clamped, the pair of grooves are exactly formed into trapezoidal grooves that match the shape of the strand. The strand steel wire passes through the grooves, and multiple wrapping tapes are fixedly wrapped around the shaped strand at intervals.

[0012] Preferably, it also includes a strand anchor head. After a pair of positioning clamps shape and clamp the strand, the steel wires at the ends of the strand are anchored through the strand anchor head. The strand anchor head includes an anchor cup, a wire splitting plate disposed at one end of the anchor cup, and a wedge inserted from the other end of the anchor cup. The steel wires are divided into multiple strands by the wire splitting plate. The outer circumferential surface of the wedge is provided with multiple slots at intervals. The multiple steel wires are sequentially split by the wire splitting plate and then pass out one by one from the multiple slots. The wedge and the anchor cup are filled with adhesive material. The outer side of the anchor cup is connected to a nut with a washer by a thread.

[0013] The present invention also provides a method for manufacturing small-diameter steel wire strands, comprising the following steps:

[0014] Step 1: Using a traction device with a fixed load function, pull one end of the traction steel wire back and forth along a pair of steering devices, so that the steel wire is wound around the pulley of the steering device with the rated tension.

[0015] Step 2: Measure the mid-span sag of the steel wire according to the scale on the fixed column of the mid-span support, and verify the tension and uniformity of the steel wire deformation.

[0016] Step 3: After all the steel wires are tensioned, start shaping the steel wires from the end closest to the turning device. Use a shaping clamp to clamp the steel wires near this turning device, and use another shaping clamp to shape and press the steel wire strands from the clamping end to the other end. Then use wrapping tape to fix them at certain intervals.

[0017] Step 4: After all the steel wires have been shaped and tightened, use a shaping clamp to clamp the strands near the other end of the steering device; measure and verify the length of the strands, and cut the steel wires from the outside of a pair of shaping clamps to complete the strand weaving;

[0018] Step 5: Divide the steel wires at the end of the cable strand into multiple strands, insert them into the anchor cup through the wire dividing hole of the wire dividing plate at the bottom of the anchor head, inject adhesive material into the anchor cup, and tighten the wedge block so that the multiple grooves of the wedge block correspond one-to-one with each steel wire; after the adhesive material solidifies, test the connection performance between the steel wire and the anchor head, and the cable strand production is completed after the requirements are met.

[0019] The present invention has at least the following beneficial effects:

[0020] The small-diameter steel wire strand fabrication device and method of the present invention can be used as a means of fabricating experimental steel wire strands, providing a fabrication device for small-diameter steel wire strands in a scaled-down test model of a suspension bridge without relying on large traction equipment. This device is not only structurally sound and easy to install and apply, but also solves the problems of traditional strand fabrication requiring large machinery and demanding site conditions. This device can also be used for the fabrication and anchoring of high-strength steel wire bundles.

[0021] Other advantages, objectives and features of the present invention will become apparent in part from the following description, and in part from those skilled in the art through study and practice of the invention. Attached Figure Description

[0022] Figure 1 This is a planar layout diagram of the strand unwinding of the present invention;

[0023] Figure 2 This is an elevation view of the strand laying arrangement of the present invention;

[0024] Figure 3 A plan layout diagram of the strands for this invention is prepared;

[0025] Figure 4 This is a schematic diagram of the fixture structure of the present invention;

[0026] Figure 5 This is a schematic diagram of the elevation structure of the cable anchor head of the present invention.

[0027] Explanation of reference numerals in the attached figures:

[0028] 1. Wire feeding device; 2. Steering device; 3. Traction device; 4. Mid-span support; 5. Column; 6. Pulley; 7. Pulley support; 8. Damper; 9. Base plate; 10. Rotating shaft; 11. Fixed column; 12. Scale; 13. Crossbeam; 14. Force gauge; 15. Shaping fixture; 16. Clamping plate; 17. Groove; 18. Bolt; 19. Anchor cup; 20. Wire dividing plate; 21. Nut with washer; 22. Wedge; 23. Steel wire; 24. Wrapping tape. Detailed Implementation

[0029] To better understand the purpose, structure, and function of this invention, the invention will be further described in detail below with reference to the accompanying drawings, so that those skilled in the art can implement it based on the description.

[0030] It should be noted that, unless otherwise specified, the experimental methods described in the following embodiments are all conventional methods, and the reagents and materials described are all commercially available unless otherwise specified. In the description of this invention, the terms "lateral", "longitudinal", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0031] like Figures 1 to 5 As shown, the present invention provides a small-diameter steel wire strand manufacturing device, comprising: a wire feeding device 1 for feeding steel wire 23, the wire feeding device 1 having fixed damping so that the released steel wire 23 has a certain initial tension; a pair of turning devices 2, which are arranged opposite to each other, through which the steel wire 23 is reciprocated; a traction device 3 having a fixed load and being connected to and pulling the outer end of the steel wire 23 on the wire feeding device 1, the traction device 3 pulling the steel wire 23 to reciprocate along the pair of turning devices 2 with a rated tension until the required number of steel wires 23 for strand weaving is formed; and a shaping device for shaping and pressing the multiple steel wires 23 after winding to form the required shape and pressing force for strand weaving.

[0032] In another embodiment, the wire feeding device 1 includes a fixed block, a base plate 9 and a rotating shaft 10 rotatably mounted on the fixed block, a wire feeding disc sleeved on the rotating shaft 10, and a damper 8 mounted on the fixed block. The central axes of the base plate 9 and the rotating shaft 10 coincide, and the wire feeding disc rotates synchronously with the base plate 9 and the rotating shaft 10. The damper 8 contacts the base plate 9 to control the torque required when the base plate 9 rotates, ensuring that the steel wire 23 has initial tension when feeding.

[0033] In another embodiment, the steering device 2 includes a column 5, a pulley bracket 7 fixed to the outside of the column 5, and a pulley 6 disposed on the pulley bracket 7. The steel wire 23 is wound around the pulley 6 and changes direction through the pulley 6. The pair of columns 5 of the pair of steering devices 2 are arranged opposite to each other and the pair of pulleys 6 on the pair of columns 5 are located in the same horizontal plane.

[0034] In another embodiment, the traction device 3 includes a force gauge 14 and a traction device, and the steel wire 23 is connected in series with the force gauge 14 and the traction device. The force gauge 14 is used to ensure that the tension of the steel wire 23 is constant when it is being pulled.

[0035] In another embodiment, a mid-span support 4 is also included, which includes a pair of fixed columns 11 disposed opposite to each other on both sides of the steel wire 23, and a crossbeam 13 connecting the pair of fixed columns 11 into one unit. The pair of fixed columns 11 are located at the center of a pair of steering devices 2. Each pair of fixed columns 11 is provided with a scale 12 to measure the sag of the steel wire 23 in the mid-span. The crossbeam 131 connects the fixed columns 11 to improve the stability of the fixed columns 11, and at the same time serves as a reference surface for measuring the sag of the steel wire 23.

[0036] In another embodiment, the shaping device includes a pair of shaping clamps 15 and multiple wrapping tapes 24. The pair of shaping clamps 15 are positioned between a pair of turning devices 2 to shape and tighten the steel wire 23. Each shaping clamp 15 includes a pair of clamping plates 16 and a bolt 18 connecting the pair of clamping plates 16 into one unit. The center of each opposite surface of the pair of clamping plates 16 is provided with a groove. After the pair of clamping plates 16 are closed and tightened, the pair of grooves form a trapezoidal groove 17 that matches the shape of the strand. The strand steel wire 23 passes through the groove 17, and the multiple wrapping tapes 24 are fixedly wound around the shaped strand at intervals. After the strand steel wire 23 passes through the groove 17 and the bolt 18 is tightened, the pair of clamping plates 16 close and tighten, thus shaping and tightening the steel wire 23.

[0037] In another embodiment, a stranded anchor head is also included. After a pair of positioning clamps clamp and shape the strands, the steel wires 23 at the ends of the strands are anchored through the stranded anchor head. The stranded anchor head includes an anchor cup 19, a wire splitting plate 20 disposed at one end of the anchor cup 19, and a tightening wedge 22 inserted from the other end of the anchor cup 19. The steel wires 23 are divided into multiple strands, for example, 6 strands, by the wire splitting plate 20. The outer circumferential surface of the wedge 22 is provided with multiple slots at intervals, corresponding to the multiple strands of steel wires 23. The multiple strands of steel wires 23 are sequentially split by the wire splitting plate 20 and then pass out one by one from the multiple slots. The wedge 22 and the anchor cup 19 are filled with an adhesive material, for example, by injecting glue into the anchor cup 19 using a syringe. The outer side of the anchor cup 19 is connected to a nut 21 with a washer by a thread.

[0038] This application uses a traction device with rated tension force 3 to tension the steel wire 23, ensuring uniform stress on the steel wire 23 within the strand and consistent length after cutting. The steel wire 23 is released through a wire release reel with fixed damping, ensuring a certain initial tension and preventing slackness and twisting. The cooperation of two shaping clamps 15 and wrapping tape 24 ensures the strand is shaped according to the inner contour of the clamps with low porosity. The wire holes at the bottom of the anchor cup 19 ensure uniform distribution of the steel wire 23 within the anchor cup 19, while preventing glue leakage. The cooperation of the tightening wedge 22 and the glue ensures a secure connection between the steel wire 23 and the anchor cup 19.

[0039] The present invention also provides a method for manufacturing small-diameter steel wire strands, comprising the following steps:

[0040] Step 1: Using the traction device 3 with fixed load function, pull one end of the traction steel wire 23 back and forth along a pair of steering devices 2, so that the steel wire 23 is wound around the pulley 6 of the steering device 2 with the rated tension.

[0041] Step 2: Measure the mid-span sag of the steel wire 23 according to the scale 12 on the fixed column 11 of the mid-span support 4, and check the uniformity of the tension and deformation of the steel wire 23; the other end of the steel wire 23 is connected to the wire feeding reel, which rotates and feeds the wire as the steel wire 23 is pulled. The wire feeding reel has fixed rotation damping to ensure that the released steel wire 23 has a certain initial tension, and to prevent the steel wire 23 from loosening and twisting, which would affect the tensioning quality;

[0042] Step 3: After all the steel wires 23 are tensioned, start shaping the steel wires 23 from the turning device 2 near one end. Use the shaping clamp 15 to clamp the steel wires 23 near this turning device 2, and use another shaping clamp 15 to shape and press the steel wire strands from the clamping end to the other end. Then use wrapping tape 24 to fix them at certain intervals.

[0043] Step 4: After all the steel wires 23 have been shaped and pressed, use the shaping clamps 15 to clamp the strands near the other end of the turning device 2; measure and verify the length of the strands, and cut the steel wires 23 from the outside of a pair of shaping clamps 15 to complete the strand weaving;

[0044] Step 5: Divide the end wires 23 of the cable strand into multiple strands, for example, 6 strands, and insert them into the anchor cup 19 through the wire dividing hole of the wire dividing plate 20 at the bottom of the anchor head. Inject adhesive material, such as glue, into the anchor cup 19 using a syringe, and tighten the wedge block 22 so that the multiple slots of the wedge block 22 correspond one-to-one with each wire 23. After the adhesive material has solidified, test the connection performance between the wires 23 and the anchor head. If the requirements are met, the cable strand production is complete.

[0045] It is understood that the present invention has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of the invention. Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. It can be applied to various fields suitable for the present invention, and other modifications can be easily implemented by those skilled in the art. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and examples shown and described herein.

Claims

1. A small diameter steel wire strand making apparatus characterized by, include: A wire feeding device for feeding steel wire, the wire feeding device having fixed damping so that the released steel wire has a certain initial tension; A pair of steering devices are arranged opposite to each other, and the steel wire is reciprocated through the pair of steering devices; the steering device includes a column, a pulley bracket fixed to the outside of the column, and a pulley arranged on the pulley bracket. The steel wire is wound on the pulley and changes direction through the pulley. The pair of columns of the pair of steering devices are arranged opposite to each other and the pair of pulleys on the pair of columns are located in the same horizontal plane. A traction device has a fixed load and is connected to and pulls the outer end of the wire on the wire feeding device. The traction device pulls the wire back and forth along a pair of turning devices at a rated tension until the required number of wires for strand braiding is formed. The traction device includes a force gauge and a puller. The wire is connected in series with the force gauge and the puller. The force gauge is used to ensure that the tension is constant when the wire is pulled. A shaping device is used to shape and compress multiple steel wires after winding, so that they form the required shape and compressive force for strand weaving. The shaping device includes a pair of shaping clamps and multiple wrapping tapes. The pair of shaping clamps is set between a pair of turning devices to shape and compress the steel wires. The shaping clamps include a pair of clamping plates and a bolt connecting the pair of clamping plates into one piece. The center of the opposite surfaces of the pair of clamping plates is provided with a groove. After the pair of clamping plates are closed and clamped, the pair of grooves are exactly formed into trapezoidal grooves that match the shape of the strand. The strand steel wires pass through the grooves, and multiple wrapping tapes are fixedly wound around the shaped strands at intervals. It also includes a mid-span support, which includes a pair of fixed columns arranged opposite each other on both sides of the steel wire, a crossbeam connecting the pair of fixed columns into one piece, the pair of fixed columns being located at the center of a pair of steering devices, and each pair of fixed columns being provided with a scale to measure the sag of the steel wire mid-span. It also includes a cable strand anchor head. After a pair of positioning clamps shape and clamp the cable strands, the steel wires at the ends of the cable strands are anchored through the cable strand anchor head. The cable strand anchor head includes an anchor cup, a wire splitting plate set at one end of the anchor cup, and a wedge inserted from the other end of the anchor cup. The steel wires are divided into multiple strands by the wire splitting plate. The outer circumferential surface of the wedge is provided with multiple slots at intervals. The multiple steel wires are sequentially split by the wire splitting plate and then pass out of the multiple slots one by one. The wedge and the anchor cup are filled with adhesive material. The outer side of the anchor cup is connected to a nut with a washer by a thread.

2. The small diameter steel wire strand making apparatus of claim 1 wherein, The wire feeding device includes a fixed block, a base plate and a rotating shaft rotatably mounted on the fixed block, a wire feeding disc sleeved on the rotating shaft, and a damper mounted on the fixed block. The central axes of the base plate and the rotating shaft coincide. The wire feeding disc rotates synchronously with the base plate and the rotating shaft. The damper contacts the base plate to control the torque required when the base plate rotates, ensuring that the wire has initial tension when feeding.

3. A method for manufacturing a small-diameter steel wire strand using the manufacturing device according to claim 1, characterized by, Includes the following steps: Step 1: Using a traction device with a fixed load function, pull one end of the traction steel wire back and forth along a pair of steering devices, so that the steel wire is wound around the pulley of the steering device with the rated tension. Step 2: Measure the mid-span sag of the steel wire according to the scale on the fixed column of the mid-span support, and verify the tension and uniformity of the steel wire deformation. Step 3: After all the steel wires are tensioned, start shaping the steel wires from the end closest to the turning device. Use a shaping clamp to clamp the steel wires near this turning device, and use another shaping clamp to shape and press the steel wire strands from the clamping end to the other end. Then use wrapping tape to fix them at certain intervals. Step 4: After all the steel wires have been shaped and tightened, use a shaping clamp to clamp the strands near the other end of the steering device; measure and verify the length of the strands, and cut the steel wires from the outside of a pair of shaping clamps to complete the strand weaving; Step 5: Divide the steel wires at the end of the cable strand into multiple strands, insert them into the anchor cup through the wire dividing hole of the wire dividing plate at the bottom of the anchor head, inject adhesive material into the anchor cup, and tighten the wedge block so that the multiple grooves of the wedge block correspond one-to-one with each steel wire; after the adhesive material solidifies, test the connection performance between the steel wire and the anchor head, and the cable strand production is completed after the requirements are met.

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