Non-loose steel wire rope and production method thereof

Abstract

According to the non-loose steel wire rope and the production method thereof, through the arrangement of the galvanized steel wire mesh layer, the first fiber mesh layer, the second fiber mesh layer and the nylon loose tube, the rope strand structures of the steel wire rope from inside to outside can be effectively and correspondingly fastened together; relative movement or loosening of the inner rope strands in the steel wire rope in the stress process can be prevented, so that the integrity and stability of the steel wire rope are kept, and the anti-loosening performance of the steel wire rope is improved. Meanwhile, the inner-layer strands and the outer-layer strands are spirally wrapped and twisted in a surface contact manner, so that the contact area and the binding force between the inner-layer strands and the composite rope core and between the outer-layer strands and the inner-layer strands are increased, the interaction among the layers is more uniform under the action of external force, the situation of local stress concentration is not prone to occurring, and therefore the overall stability of the steel wire rope is improved, and the service life of the steel wire rope is prolonged. And loosening is not easily caused. And finally, the flexibility of the first fiber net layer and the second fiber net layer can improve the stress distribution in the steel wire rope, and the local stress concentration phenomenon is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of steel wire rope manufacturing, in particular to a non-loose steel wire rope and a production method thereof. Background Art

[0002] Wire rope is a component made of high-quality high-carbon steel wire or alloy steel wire twisted on a strand core in a spiral pattern to form strands, which are then twisted around the core by a stranding machine to form a rope.

[0003] However, regardless of the use of the wire rope, its strands will occasionally deform and diverge, which will cause looseness, resulting in wire breakage, wear and other problems during the use of the wire rope, thereby shortening the service life and affecting the safety of the wire rope. The reasons for the looseness of the wire rope mainly include internal factors and external factors. The internal factors are mainly the spiral torsional stress generated during the twisting process of the wire rope or the residual stress of each strand of the rope, which causes the wire rope to loosen during use; and the external factors are firstly that the wire rope may be plastically deformed due to the impact of objects or friction with hard objects during use, causing some strands to deform and diverge; secondly, when the bending radius of the wire rope is too small, the outer strands are also prone to divergence, and the inner strands may be squeezed out; in addition, when the wire rope is cut, due to improper cutting methods, stress concentration occurs at the cut point of the wire rope, causing looseness.

[0004] Therefore, it is necessary to provide a non-loose steel wire rope and a production method thereof. Summary of the invention

[0005] In view of the technical problem that the steel wire rope in the prior art is easy to become loose during use, the present invention provides a steel wire rope that does not become loose and a production method thereof.

[0006] A non-loose steel wire rope, comprising a composite rope core, an inner layer of 12 inner strands, an outer layer of 12 outer strands and a protective layer, wherein the composite rope core comprises a main rope core wire and an outer layer of core wires twisted spirally outside the main rope core wire; the main rope core wire is twisted from a plurality of carbon fiber wires; the outer layer of core wires comprises a plurality of composite fiber core wires twisted spirally outside the main rope core wire and a plurality of outer layer of steel wire bundles twisted spirally outside the composite fiber core wire; the inner layer of strands is twisted spirally outside the composite rope core in a surface contact state, and the outer layer of strands is twisted spirally outside the inner layer of strands in a surface contact state; the inner layer of strands, the outer layer of strands and the outer layer of steel wire bundles are all made of a plurality of steel strands with manganese phosphating coatings on their outer surfaces. The wires are uniformly forged and twisted, and the twist directions of the inner and outer strands are opposite; a galvanized steel wire mesh layer is arranged between the outer steel wire bundle and the composite fiber core wire, and the galvanized steel wire mesh layer is wrapped around the outside of the composite fiber core wire; a first fiber mesh layer is arranged between the inner strand layer and the composite rope core, and the first fiber mesh layer is wrapped around the outside of the composite rope core; a second fiber mesh layer is arranged between the inner strand layer and the outer strand layer, and the second fiber mesh layer is wrapped around the outside of the inner strand layer; the first fiber mesh layer and the second fiber mesh layer are both woven from ultra-high molecular polyethylene fiber wires; the protective layer comprises a nylon loose sleeve, a wear-resistant layer and a corrosion-resistant layer which are sequentially wrapped around the outside of the outer strand layer.

[0007] Preferably, the composite fiber core wire comprises a galvanized steel core and a plurality of composite fiber wires spirally twisted on the outside of the galvanized steel core; the composite fiber wire is formed by interlacing sisal fiber wire and modified sisal fiber wire; and the composite fiber wire is all impregnated with lubricating grease.

[0008] Preferably, the modification step of the modified sisal fiber yarn includes: selecting a plurality of sisal fibers, and soaking the sisal fibers in a NaOH solution with a concentration of 2wt%-3wt% for 3-4 hours, then taking out the sisal fibers and washing them with distilled water until neutral, and drying them at 70-75°C until they reach constant weight, to obtain a first pretreated sisal fiber yarn; soaking the first pretreated sisal fiber in a solution of KH-900 silane coupling agent with a concentration of 1%-2% for 2 hours, and then naturally drying the first pretreated sisal fiber at room temperature until it reaches a constant weight, to obtain a second pretreated sisal fiber; soaking the second pretreated sisal fiber in a polyvinyl alcohol aqueous solution with a concentration of 2wt%-3wt% for 2 hours, then taking out the second pretreated sisal fiber yarn and washing it with distilled water for 3-4 times, and drying it at 80°C until it reaches a constant weight, to obtain the modified sisal fiber; selecting a plurality of modified sisal fibers, and twisting them into the modified sisal fiber yarn according to a certain arrangement method.

[0009] Preferably, the outer gaps of the adjacent outer strands are filled with a special-shaped steel wire, and the space between the special-shaped steel wire and the outer strands is filled with water-blocking yarn.

[0010] Preferably, the cross-sectional diameter of the outer strand is 1.5-2 times the cross-sectional diameter of the inner strand; and the cross-sectional diameter of the inner strand is 1.5-3 times the diameter of the outer steel wire bundle.

[0011] Preferably, the outer sides of the inner strands and the outer strands are both provided with a polytetrafluoroethylene coating or a graphite fluoride coating, and the corrosion-resistant layer includes an epoxy anti-corrosion coating and a highly chlorinated polyethylene coating.

[0012] The present invention also provides a method for producing a non-loose steel wire rope, which is suitable for manufacturing a non-loose steel wire rope as described above, comprising: S1, rough drawing of wire rods, rough drawing of high-carbon steel high-quality carbon wire rods as rough drawing wire blanks; S2: heat treatment and hot-dip process of the rough drawing wire blanks to obtain heat-treated galvanized steel wires and steel wires coated with manganese-based phosphating coatings; S3: wire drawing process of the heat-treated galvanized steel wires and steel wires coated with manganese-based phosphating coatings by a wire drawing machine to obtain galvanized steel wires and steel wires coated with manganese-based phosphating coatings of different specifications. ; S4: twisting the manganese-coated phosphating coated steel wire into inner strands, outer strands and outer steel wire bundles in a certain arrangement, and straightening the twisted outer strands, center strands and outer steel wire bundles; S5: selecting a number of carbon fiber wires, and twisting the carbon fiber wires into a main rope core wire; at the same time, firstly wrapping a composite fiber core wire around the outside of the main rope core wire in a spiral twisting manner, and laying a layer of galvanized steel wire mesh on the outside of the composite fiber core wire, and finally pre-deforming the twisted outer steel wire bundle, and then And an outer layer of steel wire bundle is twisted on the outermost side in a spiral manner to obtain a composite rope core; S6: a first fiber mesh layer woven from ultra-high molecular polyethylene fiber filaments is laid on the outer side of the composite rope core and fixed by hot pressing, and then the twisted inner layer strands are pre-deformed, and then the inner layer strands are spirally twisted on the outer side of the composite rope core to form an inner layer strand layer; S7: a second fiber mesh layer woven from ultra-high molecular polyethylene fiber filaments is laid on the outer side of the inner layer strand layer and fixed by hot pressing, and then the twisted outer layer strands are pre-deformed. The pre-deformation treatment is performed, and then the outer strands are spirally twisted in a surface contact state on the outside of the inner strand layer to form an outer strand layer; wherein the deformation rates of the inner and outer strands are controlled at 75% to 85%, and the deformation rate deviation is less than 6%; S8: a nylon loose tube is put on the outside of the outer strand layer, and a wear-resistant layer and a corrosion-resistant layer are sequentially arranged on the outside of the nylon loose tube to complete the preparation of the protective layer and obtain a non-loose steel wire rope; S9: the non-loose steel wire rope is straightened to fully eliminate the residual stress.

[0013] Preferably, in step S5, the manufacturing steps of the composite fiber core wire are: step S51: select a plurality of sisal fibers and a plurality of galvanized steel wires as the galvanized steel core; step S52: select a plurality of sisal fibers among them, and twist them into sisal fiber wires according to a certain arrangement; step S53: select a plurality of sisal fibers among them, and sequentially treat the sisal fibers with alkali, KH-900 silane coupling agent and polyvinyl alcohol to obtain modified fibers, and then twist the modified fibers into modified sisal fiber wires according to a certain arrangement; step S54: interlacedly twist sisal fiber wires and modified sisal fiber wires in a ratio of 1:2 to obtain composite fiber wires, and select a plurality of composite fiber wires to spirally wrap and twist them on the outside of the galvanized steel core to obtain the composite fiber core wire.

[0014] Preferably, in step S8, the wear-resistant layer comprises: 65-75wt% glass fiber, 15-25wt% epoxy resin, 3-8wt% nano-aluminum oxide, 2-6w% silicon carbide, 0.5-2wt% coupling agent and 1-3wt% defoaming agent.

[0015] Preferably, the manufacturing process of the wear-resistant layer includes: S81: grinding nano-alumina and silicon carbide, and screening with 200 mesh to obtain nano-alumina particles and silicon carbide particles; S82: placing glass fiber, epoxy resin and the ground nano-alumina and silicon carbide in a mixer according to a ratio, and melt-blending them at a preset temperature, and then adding a coupling agent and a defoaming agent according to a ratio, mixing evenly to obtain a mixed material; S83: extruding and blow-molding the obtained mixed material, and coating it on the nylon loose tube to obtain the wear-resistant layer.

[0016] The beneficial effects of the present invention are as follows: the present invention provides a steel wire rope that does not loosen. Through the arrangement of the galvanized steel wire mesh layer, the first fiber mesh layer, the second fiber mesh layer and the nylon loose tube, the rope strand structures from the inside to the outside of the steel wire rope can be effectively fastened together, which is beneficial to prevent the internal rope strands of the steel wire rope from moving relative to each other or loosening during the stress process, thereby maintaining the integrity and stability of the steel wire rope and improving the anti-loosening performance of the steel wire rope. At the same time, the inner strands and the outer strands are both spirally twisted in a surface contact manner, increasing the contact area and bonding force between the inner strands and the composite rope core, and between the outer strands and the inner strands, so that when subjected to external force, the interaction between the layers is more uniform, and it is not easy to have local stress concentration, thereby improving the overall stability of the steel wire rope and making it more difficult to loosen. Finally, the flexibility of the first fiber mesh layer and the second fiber mesh layer enables it to undergo a certain deformation during the stress process, thereby improving the stress distribution inside the steel wire rope, helping to reduce the local stress concentration phenomenon, and improving the fatigue resistance and service life of the steel wire rope.

[0017] The present invention also provides a method for manufacturing a non-loose steel wire rope, which greatly improves the strength and structural stability of the composite rope core through a unique composite rope core design that combines carbon fiber filaments, composite fiber core filaments and galvanized steel wire mesh layers. The pre-deformation treatment and spiral twisting process of the inner and outer strands enhance the overall structural stability and anti-loosening property of the steel wire rope. The provision of nylon loose sleeves, wear-resistant layers and corrosion-resistant layers effectively prevents the loosening phenomenon caused by the breakage of the strands of the steel wire rope due to wear, corrosion and other reasons, and further improves the durability and service life of the steel wire rope. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A schematic structural diagram of a non-loose steel wire rope provided by the present invention;

[0019] Figure 2 This is a schematic structural diagram of the main rope core wire and the composite fiber core wire of the composite rope core provided by the present invention.

[0020] Figure 3 The present invention provides a schematic flow chart of a method for producing a non-loose steel wire rope.

[0021] Figure ID

[0022] 1. Composite rope core; 2. Inner strands; 3. Outer strands; 4. Galvanized steel wire mesh layer; 5. First fiber mesh layer; 6. Second fiber mesh layer; 7. Nylon loose tube; 8. Wear-resistant layer; 9. Corrosion-resistant layer; 10. Special-shaped steel wire. 11. Main rope core wire; 12. Outer core wire; 121. Composite fiber core wire; 1211. Galvanized steel core; 1212. Composite fiber wire; 122. Outer steel wire bundle; DETAILED DESCRIPTION

[0023] To further describe the present invention in detail, the following is an explanation with reference to the accompanying drawings. It is particularly noted that the embodiments described below are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0024] refer to Figure 1 As shown, a non-loose steel wire rope comprises a composite rope core 1, an inner strand layer consisting of 12 inner strands 2, an outer strand layer consisting of 12 outer strands 3, and a protective layer.

[0025] Specifically, refer to Figure 2 As shown, the composite rope core 1 includes a main rope core wire 11 and an outer core wire 12 spirally twisted outside the main rope core wire 11, and the main rope core wire is twisted from a plurality of carbon fiber wires 11, so that the main rope core wire 11 has high strength and wear resistance and can withstand greater tension.

[0026] The outer core wire 12 includes a plurality of composite fiber core wires 121 spirally twisted on the outside of the main rope core wire 11 and a plurality of outer steel wire bundles 122 spirally twisted on the outside of the composite fiber core wire 121 .

[0027] Among them, the composite fiber core 121 includes a galvanized steel core 1211 and a plurality of composite fiber filaments 1212 spirally twisted on the outside of the galvanized steel core 1211; the composite fiber filaments 1212 are formed by interlacing sisal fiber filaments and modified sisal fiber filaments; and the composite fiber filaments are all impregnated with lubricating grease.

[0028] The galvanized steel core 1211 provides good strength and rigidity for the composite fiber core 121; the composite fiber 1212 is tightly combined with the galvanized steel core 1211, which enhances the structural stability of the composite fiber core 121. At the same time, the composite fiber 1212 is dipped in lubricating grease, which can not only lubricate the fiber and slow down the wear, but also isolate the fiber surface from oxygen in the air, inhibit oxidation and rust, and thus extend the service life of the composite fiber core 121.

[0029] At the same time, the composite rope core 1 adopts a double-layer spiral twist structure, and the composite fiber core filament 121 and the outer steel wire bundle 122 are successively wound around the outside of the main rope core filament 11 in a spiral twist manner, so that the composite rope core 1 can better disperse stress when bending, reduce local stress concentration, and thus improve the bending resistance. Sisal fiber filaments and modified sisal fiber filaments have good flexibility and elasticity. Combined with the main rope core filaments made of carbon fiber, the composite rope core 1 can maintain good shape stability during bending, reduce the risk of deformation, breakage and loosening, and thus improve the anti-loosening performance of the steel wire rope. The presence of lubricating grease reduces the friction resistance between the fiber filaments and the steel wire bundle, making the rope core smoother when bending, reducing the wear caused by friction that causes the composite rope core 1 to loosen, and improving the service life of the composite rope core 1.

[0030] Wherein, the modification step of the modified sisal fiber comprises:

[0031] Step 1: Select a number of sisal fibers and soak the sisal fibers in a 2wt%-3wt% NaOH solution for 3-4 hours, then take out the sisal fibers and wash them with distilled water until they are neutral, and dry them at 70-75° C. until they reach constant weight, to obtain first pretreated sisal fiber yarns.

[0032] The sisal fiber is soaked in NaOH solution to remove impurities and waxy layers on the surface of the sisal fiber. At the same time, the activity space of the cellulose microfibrils on the fiber surface is increased, and the crystals are arranged under the action of hydrogen bonding force, thereby improving the tensile modulus of the sisal fiber. After soaking, the sisal fiber is taken out and washed with distilled water to neutrality to remove residual NaOH. Finally, the moisture content of the fiber is ensured to be stable by drying. .

[0033] Step 2: Soak the first pretreated sisal fiber in a solution of KH-900 silane coupling agent with a concentration of 1%-2% for 2 hours, and then naturally dry the first pretreated sisal fiber at room temperature until it reaches a constant weight to obtain a second pretreated sisal fiber.

[0034] The functional groups in silane coupling agent KH-900 can react with the hydroxyl groups on the surface of sisal fiber to form chemical bonds. Due to the chemical bonding of silane coupling agent, the molecular structure of sisal fiber is strengthened, thereby improving the strength and toughness of sisal fiber. At the same time, silane coupling agent can form a dense waterproof layer on the surface of sisal fiber, which can prevent water from penetrating into the fiber, thereby improving the water resistance of sisal fiber.

[0035] Step 3: Soak the second pretreated sisal fiber in a polyvinyl alcohol aqueous solution with a concentration of 2wt%-3wt% for 2 hours, then take out the second pretreated sisal fiber and wash it with distilled water for 3-4 times, and dry it at 80°C until it reaches constant weight to obtain the modified sisal fiber.

[0036] Polyvinyl alcohol is a high molecular polymer with good water solubility. At an appropriate concentration, the PVA aqueous solution can penetrate into the internal structure of the sisal fiber. After the PVA solution penetrates into the fiber, along with the evaporation of water and the solidification of PVA, it will form a thin bonding layer between the fibers. This bonding layer can make the fibers more closely combined to prevent the fibers from loosening. At the same time, after the PVA aqueous solution is combined with the sisal fiber, the flexibility and plasticity of the fiber can be significantly improved, which is conducive to enhancing the wear resistance, tear strength and bending resistance of the composite fiber filament 1212 made of modified sisal fiber.

[0037] Step 4: Select a number of modified sisal fibers and twist them into the modified sisal fiber yarns according to a certain arrangement.

[0038] The composite fiber 1212 is made by interlacing and twisting sisal fiber and modified sisal fiber. The composite fiber has strong flexibility, high strength, tight structure and is not easy to loosen. At the same time, it has oil storage characteristics and can store oil through dipping and coating. It also has good tensile properties.

[0039] The inner layer strands 2 are spirally twisted in surface contact on the outside of the composite rope core 1, and the outer layer strands 3 are spirally twisted in surface contact on the outside of the inner layer strands 2; the inner layer strands 2, the outer layer strands 3 and the outer layer steel wire bundle 4 are all formed by uniformly forging and twisting a number of steel wires with manganese phosphating coatings on the outer surfaces, and the twist directions of the inner layer strands 2 and the outer layer strands 3 are opposite.

[0040] The inner strands 2 and the outer strands 3 are both twisted in a surface contact spiral, which increases the contact area and bonding force between the inner strands 2 and the composite rope core 1, and between the outer strands 3 and the inner strands 2, so that when subjected to external forces, the interaction between the layers is more uniform, and local stress concentration is less likely to occur, thereby improving the overall stability of the wire rope and making it less likely to loosen. The twist directions of the inner strands 2 and the outer strands 3 are opposite, which helps to balance the torque of the wire rope during the force application process, reduce the dispersion or distortion of the wire rope caused by torque imbalance, and make it more stable and less likely to deform when subjected to torsional forces.

[0041] In this embodiment, a polytetrafluoroethylene coating or a graphite fluoride coating is provided on the outer side of the inner layer strands 2 and the outer layer strands 3, which can further enhance the lubricity and wear resistance between the inner layer strands 2 and the outer layer strands 3, reduce friction loss during use, and avoid the phenomenon of loosening of the wire rope due to severe wear of the rope strands.

[0042] A galvanized steel wire mesh layer 4 is disposed between the outer steel wire bundle 122 and the composite fiber core wire 121 , and the galvanized steel wire mesh layer 4 is wrapped around the outer side of the composite fiber core wire 121 .

[0043] The provision of the galvanized steel wire mesh layer 4 can effectively fasten the internal composite fiber core wire 121 and the main rope core wire 11 structure together, which is beneficial to prevent the composite fiber core wire 121 and the main rope core wire 11 from relative movement or loosening during the force process, thereby maintaining the integrity and stability of the composite fiber core wire 121 and the main rope core wire 11.

[0044] A first fiber mesh layer 5 is provided between the inner strand layer and the composite rope core 1, and the first fiber mesh layer 5 is wrapped around the outside of the composite rope core 1. A second fiber mesh layer 6 is provided between the inner strand layer and the outer strand layer, and the second fiber mesh layer 6 is wrapped around the outside of the inner strand layer.

[0045] The first fiber mesh layer 5 can fasten the structure of the composite rope core 1 together, which is helpful to prevent the composite rope core 1 from moving relative to each other or loosening during the stress process, thereby maintaining the integrity and stability of the composite rope core 1. The second fiber mesh layer 6 can fasten the structure in the inner strand layer together, which is helpful to prevent the structure in the inner strand layer from moving relative to each other or loosening during the stress process, thereby maintaining the integrity and stability of the structure in the inner strand layer. The flexibility of the first fiber mesh layer 5 and the second fiber mesh layer 6 enables it to undergo a certain deformation during the stress process, thereby improving the stress distribution inside the steel wire rope, helping to reduce the local stress concentration phenomenon, and improving the fatigue strength and service life of the steel wire rope.

[0046] In this embodiment, the first fiber mesh layer 5 and the second fiber mesh layer 6 are both woven from ultra-high molecular weight polyethylene fibers and have excellent strength and wear resistance.

[0047] The protective layer includes a nylon loose tube 7, a wear-resistant layer 8 and a corrosion-resistant layer 9, which are sequentially wrapped around the outer side of the outer strand layer. The nylon loose tube 7 can provide additional protection and buffering for the steel wire rope, reduce the erosion of the steel wire rope by the external medium, and also play a role in preventing the overall loosening of the steel wire rope.

[0048] The coordinated arrangement of the first fiber mesh layer 5, the second fiber mesh layer 6 and the nylon loose tube 7 can effectively prevent the components in the steel wire rope from becoming loose, thereby jointly improving the overall strength and structural stability of the steel wire rope.

[0049] Preferably, the corrosion-resistant layer 9 includes an epoxy anti-corrosion coating and a high-chlorinated polyethylene coating, which can significantly improve the anti-corrosion performance of the steel wire rope and help to extend the service life of the steel wire rope.

[0050] The outer gaps of the adjacent outer strands 3 are filled with a special-shaped steel wire 10, and the space between the special-shaped steel wire 10 and the outer strands 3 is filled with water-blocking yarn (not shown in the figure).

[0051] The filling of the special-shaped steel wire 10 effectively fills the gap between the outer strands 3, reduces the looseness and deformation of the steel wire rope due to vibration or external force during use, thereby enhancing the overall structural stability of the steel wire rope and avoiding looseness. The filling of the water-blocking yarn plays a good role in water-blocking and moisture-proofing, effectively preventing moisture from penetrating into the interior of the steel wire rope, and avoiding the performance degradation or damage of the steel wire rope caused by moisture erosion.

[0052] refer to Figure 3 As shown, the present invention also provides a method for producing a non-loose steel wire rope, which is suitable for manufacturing a non-loose steel wire rope as described above, comprising:

[0053] Step S1, rough drawing of wire rods, rough drawing of high-carbon steel high-quality carbon wire rods as rough drawing wire blanks.

[0054] Step S2: performing heat treatment and hot-dip process on the rough drawn wire blank to obtain heat-treated galvanized steel wire and steel wire coated with manganese phosphating coating.

[0055] Step S3: Using a wire drawing machine to draw the heat-treated galvanized steel wire and the manganese-phosphorized steel wire, galvanized steel wire and manganese-phosphorized steel wire of different specifications are obtained. Heat treatment can improve the internal structure of the steel wire, improve its mechanical properties and processing properties. The hot-dip process can form a protective film on the surface of the steel wire to enhance its corrosion resistance and wear resistance.

[0056] Step S4: twisting the manganese-phosphating coated steel wire into inner strands 2, outer strands 3 and outer steel wire bundles 122 in a certain arrangement, and straightening the twisted outer strands 3, center strands 2 and outer steel wire bundles 122.

[0057] The manganese-coated phosphate-coated steel wire is twisted into inner strands 2, outer strands 3 and outer steel wire bundles 122 in a certain arrangement, which can enhance the compactness of the steel wire strands and the stability of the overall structure. The twisted steel wire strands are straightened to eliminate the bending and distortion generated during the twisting process, improve the accuracy of the straight line and the uniformity of the overall structure, and thus make the inner strands 2, outer strands 3 and outer steel wire bundles 122 less likely to loosen.

[0058] Step S5: select a number of carbon fiber filaments and twist the carbon fiber filaments into a main rope core filament 11; at the same time, firstly wrap the composite fiber core filament 121 in a spiral twisting manner on the outside of the main rope core filament 11, and lay a layer of galvanized steel wire mesh 4 on the outside of the composite fiber core filament 121, and finally pre-deform the twisted outer steel wire bundle 122, and then spirally twist an outer layer of steel wire bundle 122 on the outermost side to obtain a composite rope core 1.

[0059] The combination of carbon fiber filaments, composite fiber core filaments 121 and galvanized steel wire mesh layer 4 can significantly improve the strength and overall stability of the rich composite rope core 1. The pre-deformation treatment can further enhance the elasticity and deformation resistance of the rope core, making it more stable and reliable in subsequent use.

[0060] The manufacturing steps of the composite fiber core 121 are as follows:

[0061] Step S51: Select a number of sisal fibers and a number of galvanized steel wires as the galvanized steel core 1211 .

[0062] Step S52: selecting a number of sisal fibers and twisting them into sisal fiber yarns according to a certain arrangement.

[0063] Step S53: selecting a number of sisal fibers, and sequentially subjecting the sisal fibers to alkali treatment, KH-900 silane coupling agent treatment, and polyvinyl alcohol treatment to obtain modified fibers, and then twisting the modified fibers into modified sisal fiber yarns according to a certain arrangement.

[0064] Step S54: interlacing and twisting sisal fiber yarns and modified sisal fiber yarns at a ratio of 1:2 to obtain composite fiber yarns 1212, and selecting a number of composite fiber yarns 1212 to spirally wrap around the outside of the galvanized steel core 1211 to obtain the composite fiber core yarn 121.

[0065] Step S6: Lay a first fiber mesh layer 5 woven from ultra-high molecular polyethylene fibers on the outside of the composite rope core 1 and fix it with hot pressing, then pre-deform the twisted inner strands 2, and then spirally twist the inner strands on the outside of the composite rope core to form an inner strand layer.

[0066] Step S7: Lay a second fiber mesh layer 6 woven from ultra-high molecular polyethylene fiber filaments on the outside of the inner strand layer and fix it with hot pressing, and then pre-deform the twisted outer strands 3, and then spirally twist the outer strands 3 in surface contact on the outside of the inner strand layer to form an outer strand layer; wherein the deformation rates of the inner strands 2 and the outer strands 3 are controlled at 75% to 85%, and the deformation rate deviation is less than 6%.

[0067] Laying the first fiber mesh layer 5 and the second fiber mesh layer 6 woven from ultra-high molecular polyethylene fibers and hot pressing them can enhance the wear resistance and tear resistance of the inner and outer strands, and help prevent the inner and outer strands from loosening. Pre-deforming the inner strands 2 and the outer strands 3 can better adapt to the subsequent inner and outer strand twisting process, and can better adapt to the stretching and bending deformation during use, improve the compactness and stability of the overall structure, and extend the service life of the wire rope.

[0068] Step S8: Put a nylon loose tube on the outside of the outer strand layer, and sequentially set a wear-resistant layer and a corrosion-resistant layer on the outside of the nylon loose tube to complete the preparation of the protective layer and obtain a non-loose steel wire rope.

[0069] Wherein, in step S8, the wear-resistant layer comprises: 65-75wt% glass fiber, 15-25wt% epoxy resin, 3-8wt% nano-aluminum oxide, 2-6w% silicon carbide, 0.5-2wt% coupling agent and 1-3wt% defoaming agent.

[0070] Specifically, the manufacturing process of the wear-resistant layer 8 includes:

[0071] Step S81: Grind the nano-aluminum oxide and silicon carbide, and screen them with 200 mesh to obtain nano-aluminum oxide particles and silicon carbide particles. Grinding and screening helps to ensure that the particles in the wear-resistant layer are evenly distributed and improve the overall performance of the obtained wear-resistant layer.

[0072] Step S82: glass fiber, epoxy resin, ground nano-alumina and silicon carbide are placed in a mixer according to the ratio, melt-blended at a preset temperature, and then coupling agent and defoamer are added according to the ratio, and mixed evenly to obtain a mixed material. After melt blending, various materials can be fully mixed and form a good interface bond, thereby improving the overall strength and wear resistance of the wear-resistant layer. Coupling agent and defoamer help to further improve the interface bonding force and density of the wear-resistant layer, while eliminating bubbles and defects in the mixture.

[0073] Step S83: Extruding and blow-molding the obtained mixed material, and coating the mixed material on the nylon loose tube to obtain the wear-resistant layer 8. The obtained wear-resistant layer can be closely attached to the nylon loose tube to form a strong protective layer.

[0074] By providing the wear-resistant layer 8 with good wear resistance, it is possible to prevent the wire rope from being worn and causing the rope strands to be damaged or broken and become loose, thereby increasing the life of the wire rope.

[0075] Step S9: straightening the non-loose steel wire rope to fully eliminate residual stress. Straightening the steel wire rope can fully eliminate the residual stress generated during the preparation process, which helps to improve the overall stability and service life of the steel wire rope.

[0076] The present invention provides a method for manufacturing a non-loose steel wire rope, and through a unique composite rope core 1 design, combines carbon fiber filaments, composite fiber core filaments and a galvanized steel wire mesh layer 4, greatly improving the strength of the rope core and the stability of the structure. The pre-deformation treatment and spiral twisting process of the inner layer strands 2 and the outer layer strands 3 enhance the overall structural stability and anti-loosening property of the steel wire rope. The provision of the nylon loose sleeve 7, the wear-resistant layer 8 and the corrosion-resistant layer 9 effectively prevents the loosening phenomenon caused by the breakage of the rope strands due to wear, corrosion and the like, and further improves the durability and service life of the steel wire rope.

[0077] The preferred embodiments of the present invention disclosed above are only used to help explain the present invention, and do not limit the invention to the specific implementation methods described. Obviously, other modifications and changes can be made according to the content of this specification. The embodiments selected and specifically described in this specification are to better explain the principles and practical applications of the present invention, so that technicians in the relevant technical field can understand and use the present invention well. It is not a limitation of the present invention. Any simple deformation of the present invention belongs to the protection scope of the present invention.

Claims

1. A steel wire rope that is not loose, comprising a composite rope core, an inner layer consisting of 12 inner layers, an outer layer consisting of 12 outer layers, and a protective layer, characterized in that: The composite rope core comprises a main rope core wire and an outer core wire helically twisted outside the main rope core wire; the main rope core wire is twisted from a plurality of carbon fiber wires; the outer core wire comprises a plurality of composite fiber core wires helically twisted outside the main rope core wire and a plurality of outer steel wire bundles helically twisted outside the composite fiber core wire; The inner strands are spirally twisted on the outside of the composite rope core in a surface contact state, and the outer strands are spirally twisted on the outside of the inner strands in a surface contact state; the inner strands, outer strands and outer steel wire bundles are all formed by uniformly forging and twisting a number of steel wires with manganese phosphating coatings on the outer surfaces, and the twist directions of the inner strands and the outer strands are opposite; A galvanized steel wire mesh layer is arranged between the outer steel wire bundle and the composite fiber core wire, and the galvanized steel wire mesh layer is wrapped around the outside of the composite fiber core wire; A first fiber mesh layer is arranged between the inner layer strand layer and the composite rope core, and the first fiber mesh layer is wrapped around the outside of the composite rope core; a second fiber mesh layer is arranged between the inner layer strand layer and the outer layer strand layer, and the second fiber mesh layer is wrapped around the outside of the inner layer strand layer; the first fiber mesh layer and the second fiber mesh layer are both woven from ultra-high molecular polyethylene fiber filaments; The protective layer comprises a nylon loose tube, a wear-resistant layer and a corrosion-resistant layer which are sequentially wrapped around the outer side of the outer strand layer.

2. A non-loose steel wire rope according to claim 1, characterized in that: The composite fiber core wire comprises a galvanized steel core and a plurality of composite fiber wires spirally twisted on the outside of the galvanized steel core; the composite fiber wire is formed by interlacing sisal fiber wire and modified sisal fiber wire; and the composite fiber wire is all dipped in lubricating grease.

3. A non-loose steel wire rope according to claim 2, characterized in that: The modification step of the modified sisal fiber comprises: selecting a plurality of sisal fibers, and soaking the sisal fibers in a 2wt%-3wt% NaOH solution for 3-4 hours, then taking out the sisal fibers and washing them with distilled water until they are neutral, and drying them at 70-75° C. until they reach a constant weight, to obtain first pretreated sisal fiber strands; The first pretreated sisal fiber is immersed in a solution of a 1%-2% KH-900 silane coupling agent for 2 hours, and then the first pretreated sisal fiber is naturally dried at room temperature until it reaches a constant weight, thereby obtaining a second pretreated sisal fiber; The second pretreated sisal fiber is immersed in a polyvinyl alcohol aqueous solution with a concentration of 2wt%-3wt% for 2 hours, and then the second pretreated sisal fiber is taken out and washed with distilled water for 3-4 times, and dried at 80°C until it reaches a constant weight, to obtain the modified sisal fiber; A number of modified sisal fibers are selected and twisted into the modified sisal fiber yarns according to a certain arrangement.

4. The steel wire rope that does not loosen according to claim 1, characterized in that: The outer gaps of the adjacent outer layer strands are filled with a special-shaped steel wire, and the space between the special-shaped steel wire and the outer layer strands is filled with water-blocking yarn.

5. The steel wire rope that does not loosen according to claim 1, characterized in that: The cross-sectional diameter of the outer strand is 1.5-2 times the cross-sectional diameter of the inner strand; and the cross-sectional diameter of the inner strand is 1.5-3 times the diameter of the outer steel wire bundle.

6. The steel wire rope that does not loosen according to claim 1, characterized in that: The outer sides of the inner strands and the outer strands are both provided with a polytetrafluoroethylene coating or a fluorinated graphite coating, and the corrosion-resistant layer includes an epoxy anti-corrosion coating and a highly chlorinated polyethylene coating.

7. A method for producing a non-loose steel wire rope, suitable for manufacturing a non-loose steel wire rope as claimed in claim 1, characterized in that: include: S1, wire rod rough drawing, rough drawing of high carbon steel high quality carbon wire rod as rough drawing wire blank; S2: heat treatment and hot-dip process are performed on the rough drawn wire blank to obtain heat-treated galvanized steel wire and steel wire coated with manganese phosphating coating; S3: using a wire drawing machine to perform a wire drawing process on the heat-treated galvanized steel wire and the manganese-phosphorized coated steel wire to obtain galvanized steel wire and manganese-phosphorized coated steel wire of different specifications; S4: twisting the manganese-based phosphating coated steel wire into inner strands, outer strands and outer steel wire bundles in a certain arrangement, and straightening the twisted outer strands, center strands and outer steel wire bundles; S5: Select a number of carbon fiber filaments and twist the carbon fiber filaments into a main rope core filament; at the same time, firstly wrap a composite fiber core filament in a spiral twisting manner outside the main rope core filament, and lay a layer of galvanized steel wire mesh on the outside of the composite fiber core filament, and finally pre-deform the twisted outer steel wire bundle, and then spirally twist an outer steel wire bundle on the outermost side to obtain a composite rope core; S6: laying a first fiber mesh layer woven from ultra-high molecular weight polyethylene fibers on the outside of the composite rope core and hot pressing and fixing it, and then pre-deforming the inner strands obtained by twisting, and then spirally twisting the inner strands on the outside of the composite rope core to form an inner strand layer; S7: Laying a second fiber mesh layer woven from ultra-high molecular polyethylene fibers on the outside of the inner strand layer and hot pressing and fixing it, and then pre-deforming the twisted outer strands, and then spirally twisting the outer strands in a surface contact state on the outside of the inner strand layer to form an outer strand layer; wherein the deformation rates of the inner strands and the outer strands are controlled at 75% to 85%, and the deformation rate deviation is less than 6%; S8: Put a nylon loose tube on the outside of the outer strand layer, and sequentially set a wear-resistant layer and a corrosion-resistant layer on the outside of the nylon loose tube to complete the preparation of the protective layer, and obtain a non-loose steel wire rope; S9: Straighten the non-loose steel wire rope to fully eliminate residual stress.

8. The method for manufacturing a non-loose steel wire rope according to claim 7, characterized in that: In step S5, the manufacturing steps of the composite fiber core wire are: Step S51: selecting a plurality of sisal fibers and a plurality of galvanized steel wires as galvanized steel cores; Step S52: selecting a number of sisal fibers and twisting them into sisal fiber yarns according to a certain arrangement; Step S53: selecting a number of sisal fibers, and sequentially subjecting the sisal fibers to alkali treatment, KH-900 silane coupling agent treatment, and polyvinyl alcohol treatment to obtain modified fibers, and then twisting the modified fibers into modified sisal fiber yarns according to a certain arrangement; Step S54: interlacing and twisting sisal fiber yarns and modified sisal fiber yarns at a ratio of 1:2 to obtain composite fiber yarns, and selecting a number of composite fiber yarns to spirally wrap around the outer side of the galvanized steel core to obtain the composite fiber core yarn.

9. The method for manufacturing a non-loose steel wire rope according to claim 7, characterized in that: In step S8, in step S8, the wear-resistant layer includes: 65-75wt% glass fiber, 15-25wt% epoxy resin, 3-8wt% nano-aluminum oxide, 2-6w% silicon carbide, 0.5-2wt% coupling agent and 1-3wt% defoaming agent.

10. The method for manufacturing a non-loose steel wire rope according to claim 9, characterized in that: The manufacturing process of the wear-resistant layer comprises: S81: grinding the nano-alumina and silicon carbide, and screening with 200 mesh to obtain nano-alumina particles and silicon carbide particles; S82: placing glass fiber, epoxy resin, ground nano-alumina and silicon carbide in a mixer according to a ratio, and melting and blending at a preset temperature, and then adding a coupling agent and a defoaming agent according to a ratio, and mixing evenly to obtain a mixed material; S83: Extruding and blow-molding the obtained mixed material, and coating it on the nylon loose tube to obtain the wear-resistant layer.

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