A non-loosening steel wire rope and its manufacturing method

Abstract

This invention provides a non-loosening steel wire rope and its manufacturing method. By incorporating a galvanized steel wire mesh layer, a first fiber mesh layer, a second fiber mesh layer, and a nylon loose sleeve, the various strands of the steel wire rope are effectively and correspondingly secured together from the inside out. This helps prevent relative movement or loosening of the internal strands during stress, thus maintaining the integrity and stability of the steel wire rope and improving its anti-loosening performance. Simultaneously, the inner and outer strands are spirally twisted in a surface-contact manner, increasing the contact area and bonding force between the inner strands and the composite core, and between the outer strands and the inner strands. This results in more uniform interaction between the layers under external force, reducing the likelihood of localized stress concentration and improving the overall stability of the steel wire rope, making it less prone to loosening. Finally, the flexibility of the first and second fiber mesh layers improves the stress distribution within the steel wire rope, reducing localized stress concentration.

Description

Technical Field

[0001] This invention relates to the field of wire rope manufacturing technology, and in particular to a non-loosening wire rope and its production method. Background Technology

[0002] Steel wire rope is a component made by twisting high-quality high-carbon steel wire or alloy steel wire in a spiral pattern onto a core to form rope strands, and then twisting the strands around the core using a twisting machine to form a rope.

[0003] However, regardless of the type of wire rope, its strands may occasionally deform and loosen during use, leading to problems such as broken wires and wear, thus shortening its service life and affecting its safety. The causes of wire rope loosening mainly include internal and external factors. Internal factors primarily involve the helical torsional stress generated during the wire rope twisting process or the residual stress in each strand, causing loosening during use. External factors include: firstly, the wire rope may undergo plastic deformation due to impacts or friction with hard objects, causing some strands to deform and loosen; secondly, when the bending radius of the wire rope is too small, the outer strands are also prone to loosening, while the inner strands may be squeezed out; furthermore, improper cutting methods can cause stress concentration at the cut point, leading to loosening.

[0004] Therefore, it is necessary to provide a non-loosening steel wire rope and its production method. Summary of the Invention

[0005] To address the technical problem of existing steel wire ropes easily loosening during use, this invention provides a non-loosening steel wire rope and its production method.

[0006] A non-loosening steel wire rope includes a composite core, an inner layer of 12 inner strands, an outer layer of 12 outer strands, and a protective layer. The composite core includes a main core wire and an outer core wire spirally twisted around the main core wire. The main core wire is made of several carbon fiber filaments twisted together. The outer core wire includes several composite fiber core filaments spirally twisted around the main core wire and several outer steel wire bundles spirally twisted around the composite fiber core filaments. The inner strands are spirally twisted around the outside of the composite core in surface contact, and the outer strands are spirally twisted around the outside of the inner strands in surface contact. The inner strands, outer strands, and outer steel wire bundles are all made of several steel wires with a manganese phosphate coating on their outer surface. The inner and outer strands are uniformly forged and twisted, with opposite twist directions. A galvanized steel wire mesh layer is provided between the outer steel wire bundle and the composite fiber core, and the galvanized steel wire mesh layer wraps around the outside of the composite fiber core. A first fiber mesh layer is provided between the inner strand layer and the composite rope core, and the first fiber mesh layer wraps around the outside of the composite rope core. A second fiber mesh layer is provided between the inner and outer strand layers, and the second fiber mesh layer wraps around the outside of the inner strand layer. Both the first and second fiber mesh layers are woven from ultra-high molecular weight polyethylene fibers. The protective layer includes 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 includes a galvanized steel core and several composite fiber filaments spirally twisted around the outside of the galvanized steel core; the composite fiber filaments are made of sisal fiber filaments and modified sisal fiber filaments intertwined and twisted; and all the composite fiber filaments are impregnated with lubricating grease.

[0008] Preferably, the modification steps of the modified sisal fiber filaments include: selecting a number of sisal fibers and soaking them in a 2wt%-3wt% NaOH solution for 3-4 hours; then removing the sisal fibers and washing them with distilled water until neutral; drying them at 70-75℃ until constant weight is reached to obtain first pretreated sisal fiber filaments; soaking the first pretreated sisal fibers in a 1%-2% KH-900 silane coupling agent solution for 2 hours; then naturally drying the first pretreated sisal fibers at room temperature until constant weight is reached to obtain second pretreated sisal fibers; soaking the second pretreated sisal fibers in a 2wt%-3wt% polyvinyl alcohol aqueous solution for 2 hours; then removing the second pretreated sisal fiber filaments and washing them with distilled water 3-4 times; drying them at 80℃ until constant weight is reached to obtain the modified sisal fibers; and selecting a number of modified sisal fibers and twisting them into the modified sisal fiber filaments according to a certain arrangement.

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

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

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

[0012] This invention also provides a method for producing a non-loose steel wire rope, applicable to manufacturing the non-loose steel wire rope described above, comprising: S1, rough drawing of wire rod, using high-carbon steel high-quality carbon wire rod as a rough drawing blank; S2: subjecting the rough drawing blank to heat treatment and hot-dip galvanizing processes to obtain heat-treated galvanized steel wire and steel wire with manganese phosphate coating; S3: using a wire drawing machine to perform a wire drawing process on the heat-treated galvanized steel wire and the steel wire with manganese phosphate coating to obtain galvanized steel wire and steel wire with manganese phosphate coating of different specifications. S4: Manganese-plated phosphated steel wire is twisted into inner strands, outer strands, and outer wire bundles in a specific arrangement, and the twisted outer strands, inner strands, and outer wire bundles are straightened; S5: Several carbon fiber filaments are selected and twisted into the main rope core filament; simultaneously, composite fiber core filaments are first wound around the outside of the main rope core filament in a spiral twisting manner, and a layer of galvanized steel wire mesh is laid on the outside of the composite fiber core filaments. Finally, the twisted outer wire bundle is pre-deformed. A layer of outer steel wire bundle is spirally twisted onto the outermost side to obtain a composite rope core; S6: A first fiber mesh layer woven from ultra-high molecular weight polyethylene fibers is laid on the outside of the composite rope core and hot-pressed to fix it. The inner strands obtained by twisting are then pre-deformed, and the inner strands are spirally twisted onto the outside of the composite rope core to form an inner strand layer; S7: A second fiber mesh layer woven from ultra-high molecular weight polyethylene fibers is laid on the outside of the inner strand layer and hot-pressed to fix it. The outer strands obtained by twisting are then pre-deformed. The outer strand is pre-deformed, and then spirally twisted around the outer side of the inner strand in a face-to-face contact manner to form an outer strand layer; wherein, the deformation rate of the inner and outer strands is controlled at 75% to 85%, and the deformation rate deviation is less than 6%; S8: A nylon loose sleeve is fitted on the outer side of the outer strand layer, and a wear-resistant layer and a corrosion-resistant layer are sequentially set on the outer side of the nylon loose sleeve 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 residual stress.

[0013] Preferably, in step S5, the manufacturing steps of the composite fiber core filament are as follows: Step S51: Select a number of sisal fibers and a number of galvanized steel wires as a galvanized steel core; Step S52: Select a number of sisal fibers and twist them into sisal fiber filaments according to a certain arrangement; Step S53: Select a number of sisal fibers and subject them to alkali treatment, KH-900 silane coupling agent treatment, and polyvinyl alcohol treatment in sequence to obtain modified fibers. Then, twist the modified fibers into modified sisal fiber filaments according to a certain arrangement; Step S54: Twist the sisal fiber filaments and modified sisal fiber filaments alternately in a 1:2 ratio to obtain a composite fiber filament, and select a number of composite fiber filaments to spirally wrap around the outside of the galvanized steel core to obtain the composite fiber core filament.

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

[0015] Preferably, the manufacturing process of the wear-resistant layer includes: S81: grinding nano-alumina and silicon carbide, and sieving through a 200-mesh screen 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 formula, melting and mixing at a preset temperature, and then adding coupling agent and defoamer according to a formula, and mixing evenly to obtain a mixture; S83: extruding and blow molding the obtained mixture to cover the nylon sleeve to obtain the wear-resistant layer.

[0016] The beneficial effects of this invention are as follows: This invention provides a non-loosening steel wire rope. Through the arrangement of a galvanized steel wire mesh layer, a first fiber mesh layer, a second fiber mesh layer, and a nylon loose sleeve, the various strands of the steel wire rope from the inside out can be effectively fastened together. This helps prevent relative movement or loosening of the internal strands during stress, thereby maintaining the integrity and stability of the steel wire rope and improving its anti-loosening performance. Simultaneously, both the inner and outer strands are spirally twisted in a surface-contact manner, increasing the contact area and bonding force between the inner strands and the composite core, and between the outer strands and the inner strands. This results in more uniform interaction between the layers under external force, reducing the likelihood of localized stress concentration and thus improving the overall stability of the steel wire rope, making it less prone to loosening. Finally, the flexibility of the first and second fiber mesh layers allows for certain deformation during stress, thereby improving the stress distribution within the steel wire rope, helping to reduce localized stress concentration, and improving the fatigue strength and service life of the steel wire rope.

[0017] This invention also provides a method for manufacturing a non-loosening steel wire rope. Through a unique composite core design combining carbon fiber filaments, composite fiber core filaments, and a galvanized steel wire mesh layer, the strength and structural stability of the composite core are significantly improved. The pre-deformation treatment and spiral twisting process of the inner and outer strands enhance the overall structural stability and anti-loosening properties of the steel wire rope. The inclusion of nylon loose sleeves, wear-resistant layers, and corrosion-resistant layers effectively prevents loosening caused by strand breakage due to wear and corrosion, further improving the durability and service life of the steel wire rope. Attached Figure Description

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

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

[0020] Figure 3 This is a schematic diagram of a non-loosening steel wire rope production method provided by the present invention.

[0021] Attached Figure Labels

[0022] 1. Composite rope core; 2. Inner strand; 3. Outer strand; 4. Galvanized steel wire mesh layer; 5. First fiber mesh layer; 6. Second fiber mesh layer; 7. Nylon loose sleeve; 8. Wear-resistant layer; 9. Corrosion-resistant layer; 10. Shaped steel wire; 11. Main rope core wire; 12. Outer core wire; 121. Composite fiber core wire; 1211. Galvanized steel core; 1212. Composite fiber filament; 122. Outer steel wire bundle; Detailed Implementation

[0023] To provide a more detailed description of the present invention, the following description is provided in conjunction with the accompanying drawings. It should be noted that the embodiments described below are merely some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0024] refer to Figure 1 As shown, a non-loosening steel wire rope includes a composite core 1, an inner layer consisting of 12 inner strands 2, an outer 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 around the main rope core wire 11. The main rope core wire is made of several carbon fiber filaments twisted together, which makes the main rope core wire 11 have high strength and wear resistance and can withstand greater tensile force.

[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 wires 121.

[0027] The composite fiber core 121 includes a galvanized steel core 1211 and a plurality of composite fiber filaments 1212 spirally twisted around the outside of the galvanized steel core 1211; the composite fiber filaments 1212 are made of sisal fiber filaments and modified sisal fiber filaments intertwined and twisted; and all the composite fiber filaments are impregnated with lubricating grease.

[0028] A galvanized steel core 1211 provides good strength and rigidity for the composite fiber core filament 121; the composite fiber filament 1212 is tightly bonded to the galvanized steel core 1211, enhancing the structural stability of the composite fiber core filament 121. Simultaneously, all composite fiber filaments 1212 are impregnated with lubricating grease, which not only lubricates the fibers and reduces wear, but also isolates the fiber surface from oxygen in the air, inhibiting oxidation and corrosion, thereby extending the service life of the composite fiber core filament 121.

[0029] Meanwhile, the composite rope core 1 adopts a double-layer spiral twist structure. The composite fiber core filament 121 and the outer steel wire bundle 122 are both spirally twisted around the outside of the main rope core filament 11, which allows the composite rope core 1 to better disperse stress and reduce local stress concentration when bending, thereby improving its bending resistance. Sisal fiber filaments and modified sisal fiber filaments have good flexibility and elasticity. Combined with the carbon fiber main rope core filaments, they enable the composite rope core 1 to maintain good shape stability during bending, reducing the risk of deformation, breakage, and loosening, thus improving the wire rope's anti-loosening performance. The presence of lubricating grease reduces the frictional resistance between the fiber filaments and the steel wire bundle, making the rope core smoother when bending, reducing wear caused by friction that leads to loosening of the composite rope core 1, and improving its service life.

[0030] The modification steps of the modified sisal fiber include:

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

[0032] Sisal fibers are soaked in a NaOH solution to remove impurities and the waxy layer from their surface. This process increases the space for movement of cellulose microfibers on the fiber surface, allowing them to crystallize and arrange themselves under hydrogen bonding, thereby improving the tensile modulus of the sisal fibers. After soaking, the sisal fibers are removed and washed with distilled water until neutral to remove residual NaOH. Finally, drying ensures the fiber's moisture content remains stable.

[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 let the first pretreated sisal fiber dry naturally at room temperature until it reaches constant weight to obtain the second pretreated sisal fiber.

[0034] The functional groups in the silane coupling agent KH-900 can react with the hydroxyl groups on the surface of sisal fibers to form chemical bonds. Due to the chemical bonding effect of the silane coupling agent, the molecular structure of the sisal fibers is strengthened, thereby improving their strength and toughness. Simultaneously, the silane coupling agent enables the formation of a dense, waterproof layer on the surface of the sisal fibers. This waterproof layer prevents moisture from penetrating into the fiber interior, thus improving the water resistance of the sisal fibers.

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

[0036] Polyvinyl alcohol (PVA) is a high-molecular-weight polymer with good water solubility. At appropriate concentrations, PVA aqueous solutions can penetrate the internal structure of sisal fibers. Once the PVA solution penetrates the fiber, as the water evaporates and the PVA solidifies, a thin bonding layer forms between the fibers. This bonding layer allows the fibers to bind together more tightly, preventing them from becoming loose. Simultaneously, the combination of PVA aqueous solution and sisal fibers significantly improves the fiber's flexibility and plasticity, which is beneficial for enhancing the abrasion resistance, tear strength, and bending resistance of composite fiber filament 1212 made from modified sisal fibers.

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

[0038] By interlacing sisal fibers and modified sisal fibers to form composite fiber filament 1212, the composite fiber filament possesses high flexibility, high strength, and a compact structure that is not easily loosened. At the same time, it has oil storage properties, enabling it to store oils through impregnation and coating, and also has good tensile strength.

[0039] The inner strand 2 is spirally twisted in a surface-contact manner on the outside of the composite rope core 1, and the outer strand 3 is spirally twisted in a surface-contact manner on the outside of the inner strand 2; the inner strand 2, the outer strand 3 and the outer wire bundle 4 are all uniformly forged and twisted from several steel wires with a manganese phosphate coating on their outer surface, and the twisting directions of the inner strand 2 and the outer strand 3 are opposite.

[0040] Both inner strand 2 and outer strand 3 are spirally twisted in surface contact, increasing the contact area and bonding force between inner strand 2 and composite core 1, and between outer strand 3 and inner strand 2. This makes the interaction between the layers more uniform under external force, reducing the likelihood of localized stress concentration and improving the overall stability of the wire rope, making it less prone to loosening. The opposite twisting directions of inner strand 2 and outer strand 3 help balance the torque of the wire rope during stress, reducing wire rope dispersion or twisting caused by torque imbalance, making it more stable under torsional forces and less prone to deformation.

[0041] In this embodiment, both the inner strand 2 and the outer strand 3 are provided with a polytetrafluoroethylene coating or a fluorinated graphite coating, which can further enhance the lubricity and wear resistance between the inner strand 2 and between the outer strand 3, reduce frictional loss during use, and avoid the phenomenon of wire rope loosening due to severe wear of the strands.

[0042] A galvanized steel wire mesh layer 4 is provided between the outer steel wire bundle 122 and the composite fiber core filament 121, and the galvanized steel wire mesh layer 4 wraps around the outside of the composite fiber core filament 121.

[0043] The galvanized steel wire mesh layer 4 effectively secures the internal composite fiber core wire 121 and main rope core wire 11 together, which helps prevent the composite fiber core wire 121 and main rope core wire 11 from moving or loosening relative to each other during the stress process, thereby maintaining the integrity and stability of the composite fiber core wire 121 and main rope core wire 11.

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

[0045] The first fiber mesh layer 5 firmly holds the composite rope core 1 together, preventing relative movement or loosening during stress, thus maintaining the integrity and stability of the composite rope core 1. The second fiber mesh layer 6 firmly holds the structure within the inner strands together, preventing relative movement or loosening during stress, thus maintaining the integrity and stability of the inner strand structure. The flexibility of the first fiber mesh layer 5 and the second fiber mesh layer 6 allows them to deform under stress, improving the stress distribution within the wire rope, reducing local stress concentration, and increasing the fatigue strength and service life of the wire rope.

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

[0047] The protective layer comprises a nylon loose sleeve 7, a wear-resistant layer 8, and a corrosion-resistant layer 9, which are sequentially wrapped around the outer strand layer. The nylon loose sleeve 7 provides additional protection and cushioning for the wire rope, reduces the erosion of the wire rope by external media, and also prevents the wire rope from loosening as a whole.

[0048] The combination of the first fiber mesh layer 5, the second fiber mesh layer 6, and the nylon loose sleeve 7 effectively prevents the various components inside the wire rope from becoming loose, thus improving the overall strength and structural stability of the 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 corrosion resistance of the wire rope and help extend its service life.

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

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

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

[0053] Step S1: Rough drawing of wire rod. High-carbon steel high-quality carbon wire rod is rough drawn as the rough drawing billet.

[0054] Step S2: Perform heat treatment and hot-dip galvanizing processes on the rough-drawn wire blank to obtain heat-treated galvanized steel wire and steel wire with manganese phosphate coating.

[0055] Step S3: A wire drawing machine is used to draw heat-treated galvanized steel wire and manganese-phosphated steel wire to obtain galvanized steel wire and manganese-phosphated steel wire of different specifications. Heat treatment improves the internal structure of the steel wire, enhancing its mechanical and processing properties. Hot-dip galvanizing forms a protective film on the surface of the steel wire, enhancing its corrosion resistance and wear resistance.

[0056] Step S4: Twist the manganese-plated phosphated steel wire into inner strand 2, outer strand 3 and outer wire bundle 122 in a certain arrangement, and straighten the twisted outer strand 3, inner strand 2 and outer wire bundle 122.

[0057] Manganese-plated phosphated steel wires are twisted into inner strands 2, outer strands 3, and outer wire bundles 122 in a specific arrangement, which enhances the compactness of the wire strands and the stability of the overall structure. Straightening the twisted wire strands eliminates bending and twisting that occurred during twisting, improving the accuracy of the straightness and the uniformity of the overall structure, thus making the inner strands 2, outer strands 3, and outer wire bundles 122 less prone to loosening.

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

[0059] The combined use 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 composite rope core 1. Pre-deformation treatment further enhances 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 filament 121 are as follows:

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

[0062] Step S52: Select a number of sisal fibers and twist them into sisal fiber filaments according to a certain arrangement.

[0063] Step S53: Select a number of sisal fibers and subject them to alkali treatment, KH-900 silane coupling agent treatment, and polyvinyl alcohol treatment in sequence to obtain modified fibers. Then, twist the modified fibers into modified sisal fiber filaments in a certain arrangement.

[0064] Step S54: Intertwine sisal fiber filaments and modified sisal fiber filaments in a 1:2 ratio to obtain composite fiber filament 1212, and select a number of composite fiber filaments 1212 to spirally wrap around the outside of the galvanized steel core 1211 to obtain the composite fiber core filament 121.

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

[0066] Step S7: Lay a second fiber web layer 6 woven from ultra-high molecular weight polyethylene fiber filaments on the outside of the inner layer and fix it with hot pressing. Then, pre-deform the twisted outer layer 3 and spirally twist the outer layer 3 in a face-contact manner on the outside of the inner layer to form the outer layer. The deformation rate of the inner layer 2 and the outer layer 3 is controlled between 75% and 85%, and the deformation rate deviation is less than 6%.

[0067] Laying and hot-pressing a first fiber web layer 5 and a second fiber web layer 6, woven from ultra-high molecular weight polyethylene (UHMWPE) fibers, enhances the abrasion resistance and tear resistance of the inner and outer strands, while also helping to prevent them from loosening. Pre-deforming the inner strands 2 and outer strands 3 allows them to better adapt to subsequent inner and outer strand twisting processes, better withstand tensile and bending deformations during use, improve the overall structural compactness and stability, and extend the service life of the wire rope.

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

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

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

[0071] Step S81: Grind the nano-alumina and silicon carbide, and then sieve them through a 200-mesh screen to obtain nano-alumina particles and silicon carbide particles. Grinding and sieving help ensure uniform particle distribution in the wear-resistant layer and improve the overall performance of the resulting wear-resistant layer.

[0072] Step S82: Glass fiber, epoxy resin, and ground nano-alumina and silicon carbide are placed in a mixer according to the specified ratio and melt-blended at a preset temperature. Then, coupling agent and defoamer are added according to the specified ratio, and the mixture is stirred until homogeneous to obtain a final mixture. The various materials are fully mixed through melt blending, forming a good interfacial bond, thereby improving the overall strength and wear resistance of the resulting wear-resistant layer. The coupling agent and defoamer help to further improve the interfacial bonding strength and density of the resulting wear-resistant layer, while eliminating air bubbles and defects in the mixture.

[0073] Step S83: The obtained mixture is extruded and blow-molded to coat the nylon sleeve, thus obtaining the wear-resistant layer 8. The resulting wear-resistant layer can adhere tightly to the nylon sleeve, forming a robust protective layer.

[0074] By setting a wear-resistant layer 8 with better wear resistance, the wire rope can be prevented from being damaged or broken due to wear, thus improving its service life.

[0075] Step S9: The non-loosening steel wire rope is straightened to fully eliminate residual stress. Straightening the steel wire rope effectively eliminates residual stress generated during its manufacturing process, thus improving its overall stability and service life.

[0076] This invention provides a method for manufacturing a non-loosening steel wire rope. Through a unique composite core design 1, combining carbon fiber filaments, composite fiber core filaments, and a galvanized steel wire mesh layer 4, the strength and structural stability of the core are significantly improved. The pre-deformation treatment and spiral twisting process of the inner strands 2 and outer strands 3 enhance the overall structural stability and anti-loosening properties of the steel wire rope. The inclusion of nylon loose sleeves 7, a wear-resistant layer 8, and a corrosion-resistant layer 9 effectively prevents loosening caused by strand breakage due to wear and corrosion, further improving the durability and service life of the steel wire rope.

[0077] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention and do not limit the invention to the specific implementations described. Obviously, other modifications and variations can be made based on the content of this specification. The embodiments selected and specifically described in this specification are intended to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. They are not intended to limit the invention, and any simple modifications to the invention fall within the scope of protection of this invention.

Claims

1. A non-loosening steel wire rope, comprising a composite core, an inner layer of 12 inner strands, an outer layer of 12 outer strands, and a protective layer, characterized in that, The composite rope core includes a main rope core wire and an outer core wire spirally twisted outside the main rope core wire; the main rope core wire is made of several carbon fiber filaments twisted together; the outer core wire includes several composite fiber core wires spirally twisted outside the main rope core wire and several outer steel wire bundles spirally twisted outside the composite fiber core wire. The inner strand is spirally twisted in a surface-contact manner on the outside of the composite rope core, and the outer strand is spirally twisted in a surface-contact manner on the outside of the inner strand; the inner strand, outer strand and outer wire bundle are all uniformly forged and twisted from several steel wires with a manganese phosphate coating on their outer surface, and the twisting directions of the inner strand and the outer strand are opposite. A galvanized steel wire mesh layer is provided between the outer steel wire bundle and the composite fiber core wire, and the galvanized steel wire mesh layer wraps around the outside of the composite fiber core wire; A first fiber mesh layer is provided between the inner strand layer and the composite rope core, and the first fiber mesh layer wraps around the outside of the composite rope core; a second fiber mesh layer is provided between the inner strand layer and the outer strand layer, and the second fiber mesh layer wraps around the outside of the inner strand layer; both the first fiber mesh layer and the second fiber mesh layer are woven from ultra-high molecular weight polyethylene fibers. The protective layer includes a nylon sleeve, a wear-resistant layer, and a corrosion-resistant layer, which are sequentially wrapped around the outer side of the outer layer.

2. The non-loosening steel wire rope according to claim 1, characterized in that, The composite fiber core includes a galvanized steel core and several composite fiber filaments spirally twisted around the outside of the galvanized steel core; the composite fiber filaments are made of sisal fiber filaments and modified sisal fiber filaments intertwined and twisted; and all the composite fiber filaments are impregnated with lubricating grease.

3. The non-loosening steel wire rope according to claim 2, characterized in that, The modification steps of the modified sisal fiber filament include: selecting a number of sisal fibers, 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 neutral, and drying them at 70-75℃ until constant weight is reached to obtain the first pretreated sisal fiber filament. The first pretreated sisal fiber was immersed in a solution of KH-900 silane coupling agent with a concentration of 1%-2% for 2 hours, and then the first pretreated sisal fiber was naturally dried at room temperature until constant weight was reached to obtain the second pretreated sisal fiber. The second pretreated sisal fiber was soaked in a polyvinyl alcohol aqueous solution with a concentration of 2wt%-3wt% for 2 hours. The second pretreated sisal fiber filament was then taken out and washed with distilled water 3-4 times. It was then dried at 80°C until constant weight was reached to obtain the modified sisal fiber. Several modified sisal fibers are selected and twisted into modified sisal fiber filaments according to a certain arrangement.

4. The non-loosening steel wire rope according to claim 1, characterized in that, Each of the outer gaps between adjacent outer strands is filled with a shaped steel wire, and water-resistant yarn is filled between the shaped steel wire and the outer strand.

5. The non-loosening steel wire rope according to claim 1, characterized in that, The cross-sectional diameter of the outer strand is 1.5-2 times that of the inner strand; the cross-sectional diameter of the inner strand is 1.5-3 times that of the outer wire bundle.

6. The non-loosening steel wire rope according to claim 1, characterized in that, Both the inner and outer strands are provided with a polytetrafluoroethylene coating or a fluorinated graphite coating on their outer sides. The corrosion-resistant layer includes an epoxy anti-corrosion coating and a high-chlorinated polyethylene coating.

7. A method for producing a non-loosening steel wire rope, suitable for manufacturing a non-loosening steel wire rope as described in claim 1, characterized in that, include: S1. Rough drawing of wire rod: High-carbon steel high-quality carbon wire rod is rough drawn as rough drawing of wire billet. S2: The rough wire blank is subjected to heat treatment and hot-dip galvanizing processes to obtain heat-treated galvanized steel wire and steel wire with manganese phosphate coating. S3: Using a wire drawing machine to perform a wire drawing process on heat-treated galvanized steel wire and manganese-based phosphate coated steel wire to obtain galvanized steel wire and manganese-based phosphate coated steel wire of different specifications. S4: Manganese-plated phosphated steel wire is twisted into inner strands, outer strands, and outer wire bundles in a certain arrangement, and the twisted outer strands, inner strands, and outer wire bundles are straightened. S5: Select several carbon fiber filaments and twist them into the main rope core filament; at the same time, on the outside of the main rope core filament, first wrap the composite fiber core filament in a spiral twisting manner, and lay a layer of galvanized steel wire mesh on the outside of the composite fiber core filament. Finally, pre-deform the twisted outer steel wire bundle, and then spirally twist an outer layer of steel wire bundle on the outermost side to obtain the composite rope core. S6: A first fiber mesh layer woven from ultra-high molecular weight polyethylene fiber is laid on the outside of the composite rope core and fixed by hot pressing. Then, the inner strands obtained by twisting are pre-deformed and then the inner strands are spirally twisted around the outside of the composite rope core to form an inner strand layer. S7: A second fiber web layer woven from ultra-high molecular weight polyethylene fiber filaments is laid on the outside of the inner layer and fixed by hot pressing. Then, the outer layer obtained by twisting is pre-deformed and then the outer layer is spirally twisted around the outside of the inner layer in a face-to-face contact manner to form the outer layer. The deformation rate of the inner and outer layers is controlled at 75% to 85%, and the deformation rate deviation is less than 6%. S8: A nylon loose sleeve is fitted on the outside of the outer strand layer, and a wear-resistant layer and a corrosion-resistant layer are sequentially set on the outside of the nylon loose sleeve 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 residual stress.

8. The method for producing a non-loosening steel wire rope according to claim 7, characterized in that, In step S5, the manufacturing steps of the composite fiber core are as follows: Step S51: Select a number of sisal fibers and a number of galvanized steel wires as galvanized steel cores; Step S52: Select a number of sisal fibers and twist them into sisal fiber filaments according to a certain arrangement; Step S53: Select a number of sisal fibers and subject them to alkali treatment, KH-900 silane coupling agent treatment and polyvinyl alcohol treatment in sequence to obtain modified fibers. Then, twist the modified fibers into modified sisal fiber filaments in a certain arrangement. Step S54: Intertwine sisal fiber filaments and modified sisal fiber filaments in a 1:2 ratio to obtain composite fiber filaments, and select a number of composite fiber filaments to spirally wrap around the outside of the galvanized steel core to obtain the composite fiber core filament.

9. A method for producing a non-loosening steel wire rope according to claim 7, characterized in that, In step S8, the wear-resistant layer comprises: 65-75 wt% glass fiber, 15-25 wt% epoxy resin, 3-8 wt% nano-alumina, 2-6 wt% silicon carbide, 0.5-2 wt% coupling agent, and 1-3 wt% defoamer.

10. A method for producing a non-loosening steel wire rope according to claim 9, characterized in that, The manufacturing process of the wear-resistant layer includes: S81: Nano-alumina and silicon carbide are ground and then screened with a 200-mesh sieve to obtain nano-alumina particles and silicon carbide particles; S82: Place glass fiber, epoxy resin, and ground nano alumina and silicon carbide into a mixer according to the formula, melt and blend them at a preset temperature, then add coupling agent and defoamer according to the formula, and mix evenly to obtain a mixture. S83: The obtained mixture is extruded and blow-molded to coat the nylon sleeve to obtain the wear-resistant layer.

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