A composite steel wire rope for mine hoist and a manufacturing method thereof

Abstract

The application provides a composite steel wire rope for mine hoisting and a manufacturing method thereof, the center strand is made of aramid fiber, the rope core strand twisted outside the center strand is made by twisting a plurality of high-strength fibers into a silk strip through melt spinning, the strength and tensile resistance of the composite rope core are greatly improved, the rope has good toughness and corrosion resistance, and is suitable for mine environment and high-load application. Meanwhile, a fluorinated graphite coating is arranged outside the inner layer strand, and a polytetrafluoroethylene coating is arranged outside the outer layer strand, which not only can reduce the friction between the inner layer strand, the outer layer strand, the filling strand and the special-shaped steel wire during use, but also can make the inner layer strand and the outer layer strand have excellent corrosion resistance, so that the inner layer strand and the outer layer strand can maintain good performance in harsh environment; in addition, the filling of the filling strand and the special-shaped steel wire increases the compactness of the steel wire rope, so that the overall structure of the steel wire rope is more solid and fastened, and the mechanical properties of the steel wire rope are improved.

Description

Technical Field

[0001] This invention relates to the field of wire rope manufacturing technology, specifically to a composite wire rope for mine hoisting and its manufacturing method. Background Technology

[0002] Mine hoisting wire rope refers to the steel wire rope used to connect the hoisting container and transmit power to the mine hoist. It is an important component of wire rope hoisting equipment.

[0003] Mine hoisting wire ropes are mainly used to connect hoisting containers (such as cages and skips) and hoists in mines, transmitting the power generated by the hoist to transport ore, coal, waste rock, or gangue, as well as to lift personnel, equipment, and materials. Therefore, the weights to be hoisted in mines are often very large and subject to complex stresses, including tension, bending, and torsion. This places high demands on the strength, load-bearing capacity, tensile strength, and stability of the wire ropes to ensure the safety and stability of the hoisting process.

[0004] Meanwhile, the mining environment is typically harsh, containing large amounts of corrosive media such as mine water and acidic gases. These corrosive media can severely corrode steel wire ropes, reducing their service life and safety.

[0005] Therefore, it is of great significance to manufacture a mine hoisting wire rope with high strength, high tensile strength and good corrosion resistance to ensure that the wire rope can be used safely for a long time in the mining environment. Summary of the Invention

[0006] In view of the fact that existing mine wire ropes have high requirements for strength, tensile strength and corrosion resistance due to the use environment and application scenarios, this invention proposes a composite wire rope for mine hoisting and its manufacturing method.

[0007] A composite steel wire rope for mine hoisting includes a composite core, 5 inner strands, 10 outer strands, and a protective layer. The composite core comprises a central strand woven from aramid fibers and several core strands formed by melting and drawing filaments from nylon fibers, sisal fibers, glass fibers, and polyester fibers and twisting them together. The core strands are twisted in line contact around the outer side of the central strand. The inner strands are twisted in line contact around the outer side of the composite core, and each inner strand is coated with a fluorinated graphite coating. A filler strand is placed in the outer gap between adjacent inner strands. The outer strands are twisted in surface contact around the outer side of the inner strands, and each outer strand is coated with a polytetrafluoroethylene coating. A shaped steel wire is placed in the outer gap between adjacent outer strands. The protective layer includes a corrosion-resistant layer and a wear-resistant layer. The corrosion-resistant layer is uniformly wrapped around the outer surface of the outer strands, and the wear-resistant layer is disposed on top of the corrosion-resistant layer.

[0008] Preferably, a sound-absorbing layer is further provided between the outer layer and the corrosion-resistant layer. The sound-absorbing layer includes a first rubber layer and a second rubber layer uniformly wrapped around the outside of the first rubber layer. A plurality of rubber support plates are provided between the first rubber layer and the second rubber layer, and the two ends of the rubber support plates are respectively connected to the first rubber layer and the second rubber layer.

[0009] Preferably, the rubber support plate includes a first rubber support plate and a second rubber support plate. The first rubber support plate is evenly distributed between the first rubber layer and the second rubber layer, and both ends of the first rubber support plate along the width direction are fixedly connected to the first rubber layer and the second rubber layer, respectively. The second rubber support plate is respectively disposed between two adjacent first rubber support plates, and one end of each second rubber support plate along the width direction is connected to the end of the adjacent first rubber support plate near the first rubber plate, and the other end is connected to the end of another adjacent first rubber support plate near the second rubber plate. Polyester fiber sound-absorbing cotton is filled between the first rubber support plate and the second rubber support plate.

[0010] Preferably, the inner strand includes an inner core and several outer fine steel wires spirally twisted around the inner core in line contact; the inner core includes an aramid fiber rope and several carbon fiber ropes and inner fine steel wires interlaced and spirally twisted around the outer layer of the aramid fiber rope.

[0011] Preferably, the outer strand includes an outer strand core, a plurality of middle layer coarse steel wires spirally twisted in a surface-contact manner on the outer strand core, and an outer layer coarse steel wire spirally twisted in a surface-contact manner on the outside of the middle layer coarse steel wire; the outer strand core includes a core steel wire and a plurality of inner layer coarse steel wires spirally twisted in a surface-contact manner on the outside of the core steel wire.

[0012] Preferably, the filler strand comprises a polyester fiber core and a plurality of filler steel wires uniformly twisted around the outside of the polyester fiber core in a face-to-face contact manner.

[0013] Preferably, a water-blocking yarn is provided between the outer strand and the shaped steel wire.

[0014] This invention also provides a method for manufacturing a composite steel wire rope for mine hoisting, applicable to the manufacture of the aforementioned composite steel wire rope for mine hoisting, comprising: S1, preparation of the composite rope core: selecting raw materials in the following order by weight percentage: nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant, and mixing the above raw materials, then melting and drawing them to form filaments, twisting several of the filaments together to form a core strand, and spirally wrapping the core strand around the outside of a central strand made of aramid fiber in a line-contact manner to form the composite rope core; S2, oil impregnation of the composite rope core: drying the composite rope core under vacuum conditions for 1-1.5 hours, and then pressing it under vacuum. S3. Oil immersion: High-carbon steel wire rods are roughly drawn into rough-drawn wire blanks, and then subjected to heat treatment and hot-dip galvanizing processes to obtain heat-treated galvanized steel wire. This wire is then drawn using a wire drawing machine to obtain galvanized steel wire of different specifications. S4. Twisting of inner strand 2: Aramid fiber rope, carbon fiber rope, and galvanized steel wire of appropriate specifications are selected. The aramid fiber rope and carbon fiber rope are dried, compacted by machine, and then heated and pressure-cured. Several galvanized steel wires and carbon fiber ropes of the same specifications as the carbon fiber rope are taken and arranged alternately around an aramid fiber rope and spirally twisted to obtain the inner strand core. Then, another specification of galvanized steel wire is selected... Zinc-coated steel wire is spirally twisted around the inner core in a line-contact manner to form the inner strand, and a fluorinated graphite coating is applied to the outside of the inner strand; S5, Twisting of the filler strand and outer strand: The galvanized steel wire is evenly twisted into the outer strand in a certain arrangement, and the galvanized steel wire is spirally twisted around the outside of a polyester fiber core in a surface-contact manner to form the filler strand. The galvanized steel wires of both the outer strand and the filler strand are made from round wires through die pressing and forging into irregularly shaped and regular steel wires to form compacted strands, and a polytetrafluoroethylene coating is applied to the outer layer of the outer strand; S6, Rope assembly: The twisted composite rope core and 5 inner strands are arranged using a splitter, deformed by a pre-deformer, and then the inner strands are twisted around the outside of the composite rope core using a pressing die. The 5 filler strands are evenly arranged between two inner strands. The gaps between the strands are twisted together, and then the 10 outer strands are twisted to the outside of the inner strands using a wire pressing die and compacted using a roller compactor. Then, 10 galvanized steel wires are evenly placed in the gaps between two outer strands and twisted together. Finally, the roller compactor compacts the galvanized steel wires in the gaps to form shaped steel wires. Finally, the stress is eliminated by a pre-deformer to obtain the steel wire rope body without a protective layer; S7, Oiling the surface of the steel wire rope body: Using the dip coating method, the twisted steel wire rope body is pressed into molten grease for oiling, and the dip coating time is 1-1.5h; S8, Protective layer preparation: A corrosion-resistant layer and a wear-resistant layer 51 are sequentially applied to the outside of the oiled steel wire rope body to obtain the composite steel wire rope for mine hoisting.S9. Straightening and oil content detection of wire rope: The prepared wire rope is straightened to fully eliminate residual stress; then a portion of the wire rope is cut off with a hydraulic cutter as a sample for oil content detection to check whether the oil content of the prepared wire rope meets the preset requirements.

[0015] Preferably, the specific steps of step S1 are as follows: S11, selecting raw materials in the following order by weight percentage: 40:15:5:10:4:2:2.5: nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant; S12, placing the nylon fiber, sisal fiber, glass fiber, and polyester fiber into a pulverizer for pulverization, then feeding them into a grinder for further grinding, and finally mixing the ground raw materials in a mixer to obtain a raw material mixture; S13, adding a predetermined amount of plasticizer, stearic acid, and antioxidant to the raw material mixture. After mixing, the mixture is sent to a drying device for drying. The dried mixture is extruded through the screw of a twin-screw extruder and melted into a molten spinning solution. The molten spinning solution is spun into filaments through a spinning assembly. S14. The filaments are cooled and cured by a cooling blower. The cured filaments are then wound into shape by a winding device to form a composite rope core strand. S15. Several of the prepared filaments are selected and twisted together to form a rope core strand. The rope core strand is then spirally twisted around the outside of a central strand made of aramid fiber in a line contact manner to form the composite rope core.

[0016] Preferably, the method for detecting the oil content of the wire rope in step S9 is as follows: S91: A portion of the prepared wire rope is cut off using a hydraulic cutter as a sample. After removing the protective layer, the wire rope body is separated into a core sample including a composite core and an inner strand core, and strand samples including inner strands, outer strands, filler strands, and shaped steel wires; S92: The strand samples are repeatedly soaked and heated, then dried, and the weight of the dried strand samples is measured; S93: The core sample is dried, then repeatedly soaked and heated, dried a second time, and the weight of the dried core sample is measured; S94: The soaking solution of the strand samples is filtered to obtain the filtered impurities, which are then dried and cooled, and the weight of the filtered impurities is measured; S95: Based on the weights of the strand samples and core samples before and after the operation, and the weight of the filtered impurities, the oil content of the wire rope to be tested is calculated.

[0017] The beneficial effects of this invention are as follows: This invention provides a composite steel wire rope for mine hoisting, comprising a composite core, inner strands, outer strands, filler strands, and a protective layer. The central strand made of aramid fiber improves the load-bearing capacity and tensile strength of the composite core. At the same time, the core strand, made by twisting together multiple high-strength fibers into filaments through melting and drawing, is twisted outside the central strand, greatly improving the strength and tensile strength of the composite core. This allows the composite core to withstand greater tensile force and possesses good toughness and corrosion resistance, making it suitable for mine environments and high-load applications. Meanwhile, by applying a fluorinated graphite coating to the outer layer of the inner strands and a polytetrafluoroethylene coating to the outer layer of the outer strands, friction between the inner strands, outer strands, filler strands, and shaped steel wires during use is reduced. This also gives the inner and outer strands excellent corrosion resistance, allowing them to maintain good performance in harsh environments. Furthermore, the filling with filler strands and shaped steel wires increases the density of the wire rope, making the overall structure more robust, secure, and pressure-resistant. This reduces the deflection between the inner and outer strands, ensuring sufficient support during use. The resulting wire rope has high rotational strength and correspondingly high tensile strength, improving its mechanical properties and breaking strength.

[0018] This invention also provides a method for manufacturing steel wire ropes for mine hoisting. By selecting nylon fiber, sisal fiber, glass fiber, and polyester fiber and combining them with melt-drawn strands to form a core strand, the resulting composite core rope possesses high strength and tensile strength, suitable for various mining environments and high-load applications. Simultaneously, the inner layer strands utilize a combination of aramid fiber rope, carbon fiber rope, and galvanized steel wire. This not only improves the strength of the inner layer strands but also gives them high-temperature resistance and corrosion resistance, while also reducing their weight, making the entire steel wire rope lighter, improving operational efficiency, and reducing energy consumption. Furthermore, straightening treatment eliminates residual stress in the steel wire rope, improving its straightness and performance. Oil content testing ensures that the oil content of the steel wire rope meets preset requirements, guaranteeing its lubrication and corrosion resistance during use, thus improving the manufacturing quality of the steel wire rope. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of a composite steel wire rope for mine hoisting according to the present invention;

[0020] Figure 2 for Figure 1 A magnified structural diagram of part A;

[0021] Figure 3 This is a schematic diagram of the composite rope core described in this invention;

[0022] Figure 4This is a schematic diagram of the inner layer strand 2 structure described in this invention;

[0023] Figure 5 This is a schematic diagram of the structure of the outer layer 3 described in this invention;

[0024] Figure 6 This is a schematic diagram of the structure of the filling strand described in this invention;

[0025] Figure 7 This is a schematic flowchart of a method for manufacturing a composite steel wire rope for mine hoisting according to the present invention.

[0026] Attached Figure Labels

[0027] 1. Composite rope core; 11. Center strand; 12. Rope core strand; 2. Inner layer strand; 21. Fluorinated graphite coating; 22. Aramid fiber rope; 24. Carbon fiber rope; 3. Outer layer strand; 31. Polytetrafluoroethylene coating; 4. Filler strand; 41. Polyester fiber core strand; 42. Filler steel wire; 5. Protective layer; 51. Wear-resistant layer; 52. Corrosion-resistant layer; 53. Sound-absorbing layer; 531. First rubber layer; 532. Second rubber layer; 533. Polyester fiber sound-absorbing cotton; 534. First rubber support plate; 535. Second rubber support plate; 6. Shaped steel wire. Detailed Implementation

[0028] 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.

[0029] refer to Figure 1 As shown, a composite steel wire rope for mine hoisting includes a composite core 1, 5 inner strands, 10 outer strands 3, and a protective layer 5.

[0030] For details, please refer to Figure 1 and Figure 3 As shown, the composite rope core 1 includes a central strand 11 made of aramid fiber and a rope core strand 12 made of several strands of nylon fiber, sisal fiber, glass fiber and polyester fiber formed by melt drawing and twisting; the rope core strand 12 is twisted around the outside of the central strand 11 in a line contact manner.

[0031] The core strand 11 is made of aramid fiber. Utilizing the high strength and high modulus of aramid fiber, its use as the core strand 11 significantly improves the load-bearing capacity and tensile strength of the composite rope core 1. Simultaneously, the core strand 12 is made by melting and drawing multiple high-strength fibers such as nylon fiber, sisal fiber, glass fiber, and polyester fiber into filaments and twisting them together. This allows the core strand 12 to combine the advantages of nylon fiber, sisal fiber, glass fiber, and polyester fiber, greatly enhancing the strength and tensile strength of the composite rope core 1. It also possesses good corrosion resistance, toughness, and elasticity, enabling the composite rope core 1 to withstand greater tensile and frictional forces. This makes it suitable for high-load applications in various mine hoisting operations and adaptable to the harsh environments of mines.

[0032] The inner strands 2 are twisted around the outside of the composite rope core 1 in a line-contact manner, and each inner strand 2 is coated with a fluorinated graphite coating 21. A filler strand 4 is filled into the outer gaps between adjacent inner strands 2. The fluorinated graphite coating 21 has an extremely low coefficient of friction and excellent wear resistance. Coating it onto the surface of the inner strands 2 significantly reduces friction between the inner strands 2 and adjacent inner strands 2, filler strands 4, and outer strands 3, thereby reducing frictional resistance between the strands and making the rope smoother when pulled or rotated. Simultaneously, the fluorinated graphite coating 21 exhibits good chemical stability at both room temperature and high temperature conditions and is not easily reacted with acids, alkalis, or other chemicals, allowing the inner strands 2 to maintain stable performance in the harsh environment of a mine.

[0033] Specifically, the inner strand 2 includes an inner core and several outer fine steel wires spirally twisted around the inner core in line contact; the inner core includes an aramid fiber rope 22 and several carbon fiber ropes 23 interlaced spirally twisted around the outer layer of the aramid fiber rope and the inner fine steel wires. The aramid fiber rope 22 is woven from aramid fiber filaments, and the carbon fiber rope 23 is woven from carbon fiber filaments.

[0034] Aramid fiber rope 22 provides excellent load-bearing and tensile strength for the inner strand core, maintaining good strength and toughness during repeated bending, stretching, and lifting. Carbon fiber rope 23 possesses excellent corrosion resistance, resisting the erosion of various chemicals and helping to protect the inner strand core from damage caused by harsh environmental conditions. The combined application of aramid fiber rope 22 and carbon fiber rope 23 not only improves the strength of the inner strand 2 but also endows it with high-temperature resistance and corrosion resistance, maintaining good performance in the harsh environment of mines. Simultaneously, it helps reduce the weight of the inner strand 2, making the entire wire rope lighter, improving operational efficiency, and reducing energy consumption.

[0035] The outer strand 3 is twisted around the outer side of the inner strand 2 in a surface-contact manner, and the surface of each outer strand 3 is coated with a polytetrafluoroethylene (PTFE) coating 31. This surface-contact twisting increases the contact area between the outer strands, helping to disperse stress and reduce internal stress concentration points, thereby improving the overall load-bearing capacity and rotation resistance of the wire rope. The PTFE coating has an extremely low coefficient of friction and excellent wear resistance, reducing friction between the outer strand 3 and the inner strand 2, filler strand 4, and other contact surfaces. Simultaneously, the PTFE coating exhibits excellent corrosion resistance to various chemicals, allowing the outer strand 3 to maintain good performance in harsh environments, reducing performance degradation and damage caused by external corrosion, and making it more suitable for mining environments.

[0036] Specifically, the outer strand 3 includes an outer core, several middle coarse steel wires spirally twisted around the outer core in a surface-contact manner, and an outer coarse steel wire spirally twisted around the outside of the middle coarse steel wire in a surface-contact manner. The outer core includes a core steel wire and several inner coarse steel wires spirally twisted around the outside of the core steel wire in a surface-contact manner. Through its multi-layer spiral twisting structure, the outer strand 3 is more robust and stable overall, improving its strength and load-bearing capacity. The surface contact between the steel wires helps to better distribute stress. When subjected to heavy-load lifting, the surface contact design reduces stress concentration points within the outer strand 3, thereby improving its load-bearing capacity and durability.

[0037] The design of the composite core 1, inner strand 2 and outer strand 3 gives the wire rope higher strength and corrosion resistance, and enables it to withstand larger lifting loads and harsh working environments.

[0038] The filler strand 4 includes a polyester fiber core 41 and several filler steel wires 42 uniformly twisted around the outside of the polyester fiber core in a surface-contact manner. The polyester fiber core 41 is not easily deformed within the wire rope and has oil absorption and storage properties, which can improve the supporting effect. When the wire rope is in operation, the bending or stretching of the wire rope will cause the grease in the polyester fiber core to be squeezed out, flow out and soak into the steel wires of the corresponding strands for lubrication, thereby reducing inter-strand friction and reducing noise generation.

[0039] Each adjacent outer strand 3 has a shaped steel wire 6 filling its outer gap. In this embodiment, the inner side of the shaped steel wire 6 is attached to the outer surface of the outer strand 3, and the outer side is attached to the inner surface of the protective layer 5, forming an arc-shaped structure. The filling of the strand 4 and the shaped steel wire 6 increases the density of the wire rope, making the overall structure more robust, secure, and pressure-resistant. This reduces the deflection between the inner strand 2 and the outer strand 3, ensuring sufficient support during use. The resulting wire rope has high rotational resistance and corresponding high tensile strength, improving its mechanical properties and breaking strength.

[0040] The protective layer 5 includes a corrosion-resistant layer 52 and a wear-resistant layer 51. The corrosion-resistant layer 52 is uniformly wrapped around the outer surface of the outer strand 3, and the wear-resistant layer 51 is disposed on the corrosion-resistant layer 52. The corrosion-resistant layer 52 and the wear-resistant layer 51 can protect the wire rope from the erosion and corrosion of the external environment, adapt to various harsh operating environments, and extend the service life of the wire rope.

[0041] In this embodiment, the wear-resistant layer 51 is an aluminum oxide coating, and the corrosion-resistant layer 52 is a phosphate corrosion-resistant layer. Aluminum oxide has high hardness and excellent wear resistance, which can form a high-hardness protective layer on the surface of the wire rope, effectively resisting external wear and extending the service life of the wire rope. The phosphate corrosion-resistant layer can form a dense phosphate film on the surface of the wire rope, which can effectively isolate corrosive substances in the external environment, such as moisture and oxygen, thereby extending the service life of the wire rope.

[0042] Preferably, a sound-absorbing layer 53 is further provided between the outer layer 3 and the corrosion-resistant layer 52. The sound-absorbing layer 53 includes a first rubber layer 531 and a second rubber layer 532 uniformly wrapped around the outside of the first rubber layer 531. A plurality of rubber support plates (not shown in the figure) are provided between the first rubber layer 531 and the second rubber layer 532. The two ends of the rubber support plates are respectively connected to the first rubber layer 531 and the second rubber layer 532, and the space between the rubber support plates is filled with polyester fiber sound-absorbing cotton 533.

[0043] The rubber support plate includes a first rubber support plate 534 and a second rubber support plate 535. The first rubber support plate 534 is evenly distributed between the first rubber layer 531 and the second rubber layer 532, and both ends of the first rubber support plate 534 along the width direction are fixedly connected to the first rubber layer 531 and the second rubber layer 532, respectively. The second rubber support plate 535 is respectively disposed between two adjacent first rubber support plates 534, and one end of each second rubber support plate along the width direction is connected to the end of the adjacent first rubber support plate 534 near the first rubber plate, and the other end is connected to the end of another adjacent first rubber support plate 534 near the second rubber plate. The polyester fiber sound-absorbing cotton 533 is filled between the first rubber support plate 534 and the second rubber support plate 535.

[0044] The first rubber layer 531 and the second rubber layer 532 serve as the foundation of the sound-absorbing layer 53, providing initial sound insulation and vibration reduction. The rubber material itself has certain damping properties, absorbing and reducing the transmission of sound vibrations. Simultaneously, the connection between the first rubber support plate 534 and the second rubber support plate 535 and the first rubber layer 531 and the second rubber layer 532 not only provides structural support for the sound-absorbing layer 53 but also provides good anti-compression for the wire rope, effectively improving the elastic buffering performance of the wire rope, reducing the pressure on the wire rope, and thus preventing deformation, allowing it to withstand larger loads during lifting. The gaps formed by the connection between the first rubber support plate 53, the second rubber support plate 535 and the first rubber layer 531 and the second rubber layer 532 not only further increase the propagation path and scattering of sound waves inside the material, which helps to improve sound absorption efficiency, but also provide filling gaps for the polyester fiber sound-absorbing cotton 533. By filling the gaps with polyester fiber sound-absorbing cotton 533, the sound absorption and noise reduction performance of the wire rope is greatly improved, which can effectively reduce the noise that may be generated by the internal friction of the wire rope during operation and the noise transmitted from the outside of the wire rope, thus achieving the effect of noise reduction.

[0045] A water-blocking yarn (not shown in the figure) is also provided between the outer strand 3 and the shaped steel wire 6. The water-blocking yarn expands after absorbing water and fills the gap between the outer strands 3, which can effectively prevent water from entering the wire rope and causing the wire rope to rust, making the wire rope better adaptable to the mining environment; it can also reduce the friction between the shaped steel wire 6 and the outer strand 3.

[0046] refer to Figure 6 As shown, the present invention also provides a method for manufacturing a composite steel wire rope for mine hoisting, applicable to the manufacture of a composite steel wire rope for mine hoisting as described above, comprising steps S1 to S9.

[0047] Step S1, Fabrication of Composite Rope Core 1: Select raw materials in the following order by weight percentage: nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant. Mix the above raw materials and then melt-draw them to form filaments. Twist several of the filaments together to form a rope core strand 12. Then, spirally wrap the rope core strand 12 around the outside of a central strand 11 made of aramid fiber in a line contact manner to form the composite rope core 1.

[0048] Specifically, the steps of step S1 are as follows:

[0049] Step S11: Select raw materials in the following order by weight percentage: 40:15:5:10:4:2:2.5: nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant. Glass fiber and other raw materials have certain corrosion resistance, which can further improve the corrosion resistance of the composite rope core.

[0050] Step S12: Nylon fiber, sisal fiber, glass fiber, and polyester fiber are separately crushed in a pulverizer and then ground in a mill. The ground materials are then mixed in a mixer to obtain a raw material mixture. Through the processing of the pulverizer and mill, the various fiber raw materials are refined to a smaller particle size, which helps to increase the contact area between the raw materials and improve the mixing effect.

[0051] Step S13: After adding a predetermined amount of plasticizer, stearic acid, and antioxidant to the raw material mixture and mixing, the mixture is sent to a drying device for drying. The dried mixture is then extruded through a twin-screw extruder to melt into a molten spinning solution. The molten spinning solution is then spun into filaments by a spinning assembly. The plasticizer improves the melting and processing properties of the raw material, making the filament formation more uniform and stable, which helps to improve the flexibility and fatigue resistance of the manufactured core strand 12. Stearic acid, as a lubricant, reduces friction and resistance during the melting and drawing process of the raw material, which helps to improve the smoothness and wear resistance of the manufactured core strand 12. The antioxidant inhibits the oxidation and aging process of the raw material during processing and use.

[0052] Step S14: The filaments are cooled and cured by cooling air blowing. The cured filaments are then wound into shape by a winding device to form a composite rope core of 1 strand.

[0053] Step S15: Select several prepared filaments and twist them together to form a core strand 12. Then, spirally twist the core strand 12 around the outside of a central strand 11 made of aramid fiber in a line-contact manner to form the composite rope core 1. By using a central strand 11 made of aramid fiber, the high strength and high modulus characteristics of aramid fiber can significantly improve the load-bearing capacity and tensile strength of the composite rope core 1.

[0054] Step S2, Oil Impregnation of Composite Rope Core 1: The composite rope core 1 is dried under vacuum for 1-1.5 hours, and then impregnated with oil under vacuum pressure for 2-2.5 hours to obtain a composite rope core 1 with high oil content. Drying the composite rope core 1 under vacuum effectively removes moisture and volatile substances. The vacuum impregnation process ensures that the oil is evenly distributed among the strands of the composite rope core 1.

[0055] Step S3, Obtaining galvanized steel wire: High-carbon steel high-quality carbon wire rod is roughly drawn as a rough drawing billet, and the rough drawing billet is subjected to heat treatment and hot-dip galvanizing processes to obtain heat-treated galvanized steel wire, which is then drawn by a wire drawing machine to obtain galvanized steel wire of different specifications.

[0056] Step S4, Twisting of inner strand 2: Select aramid fiber rope, carbon fiber rope and galvanized steel wire of appropriate specifications; dry the aramid fiber rope 22 and carbon fiber rope 23, compact them with a machine and heat and press them to solidify and form them; take several galvanized steel wires and carbon fiber ropes 23 of the same specifications as the carbon fiber rope and arrange them alternately around an aramid fiber rope 22 and spirally twist the aramid fiber rope 22 to obtain the inner strand core; then select another specification of galvanized steel wire and spirally twist it around the inner strand core in a line contact manner to obtain inner strand 2, and coat the inner strand 2 with a fluorinated graphite coating 21.

[0057] Step S5, Twisting of filler strand 44 and outer strand 3: Galvanized steel wire is evenly twisted into outer strand 3 in a certain arrangement. Galvanized steel wire is spirally twisted in a face-contact manner around the outside of a polyester fiber core 41 to form filler strand 44. The galvanized steel wires of outer strand 3 and filler strand 44 are both made from round wires through molding and forging into irregularly shaped and regular steel wires to form compacted strands. A polytetrafluoroethylene coating 31 is then applied to the outer layer of outer strand 3.

[0058] Step S6, Rope Assembly: Arrange the twisted composite core 1 and 5 inner strands 2 using a splitter, deform them using a pre-deformer, then use a pressing die to twist the inner strands 2 to the outside of the composite core 1. Evenly place the 5 filler strands 44 in the gap between two inner strands 2 and twist them together. Then, use a pressing die to twist 10 outer strands 3 to the outside of the inner strands 2 and compact them using a roller compactor. Next, evenly place 10 galvanized steel wires in the gap between two outer strands 3 and twist them together. Finally, use a roller compactor to compact the galvanized steel wires in the gap to form shaped steel wires 6. Finally, use a pre-deformer to eliminate stress and obtain the steel wire rope body without the protective layer 5.

[0059] Step S7: Oiling the surface of the wire rope body: The twisted wire rope body is pressed into the molten grease for oiling using the dip coating method. The dip coating time is 1-1.5 hours.

[0060] Step S8: Preparation of protective layer 5: A corrosion-resistant layer 52 and a wear-resistant layer 51 are sequentially applied to the outside of the oiled wire rope body to obtain the composite wire rope for mine hoisting.

[0061] Step S9: Straightening and Oil Content Testing of the Wire Rope: The prepared wire rope is straightened to fully eliminate residual stress. Straightening eliminates residual stress, improving its straightness and performance. Oil content testing ensures the wire rope's oil content meets preset requirements, guaranteeing its lubricity and corrosion resistance during use, and ensuring the manufacturing quality of the wire rope.

[0062] Specifically, the method for detecting the oil content of the wire rope in step S9 is as follows:

[0063] S91: A portion of the prepared wire rope is cut off using a hydraulic cutter as a sample. After removing the protective layer 5, the wire rope body is separated into a core sample including a composite core 1, a polyester fiber strand core 41, an aramid fiber rope 22, and a carbon fiber rope 23, and a strand sample including an inner strand 2, an outer strand 3, a filler strand 4, and a shaped steel wire 6.

[0064] S92: Repeat the soaking and heating process on the strand sample multiple times, then dry it and weigh the dried strand sample. The repeated soaking and heating process removes excess grease from the surface of the strand sample and immerses the grease in the soaking solution.

[0065] S93: After drying the rope core sample, repeat the soaking and heating operation multiple times, dry it a second time, and weigh the dried rope core sample.

[0066] S94: Filter the soaking solution of the strand sample, obtain the filtered impurities, dry and cool the filtered impurities, and then weigh the filtered impurities.

[0067] S95: Calculate the oil content of the wire rope to be tested by measuring the weight before and after the operation and the weight of filtered impurities based on the strand and core samples.

[0068] Specifically, the formula for calculating the oil content of the wire rope is as follows:

[0069] M=[(m1-m3)+(m4-m5)] / (m5+m3)×100%;

[0070] Where M represents the oil content of the steel wire rope to be tested; m1 represents the weight of the strand sample before oil removal; m3 represents the weight of the strand sample after oil removal; m4 represents the weight of the core sample after moisture removal; and m5 represents the weight of the core sample after grease removal.

[0071] The above-disclosed embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of the present invention. Therefore, any equivalent variations made in accordance with the claims of the present invention are still within the scope of the present invention.

Claims

1. A composite steel wire rope for mine hoisting, comprising a composite core, 5 inner strands, 10 outer strands, and a protective layer, characterized in that, include: The composite rope core includes a central strand woven from aramid fibers and a core strand made of several strands of nylon fibers, sisal fibers, glass fibers, and polyester fibers that are melt-drawn and twisted together; the core strands are twisted around the outside of the central strand in a line-contact manner. The inner strands are twisted around the outside of the composite rope core in a line-contact manner, and the surface of each inner strand is coated with a fluorinated graphite coating; a filler strand is filled in the outer gap between adjacent inner strands. The outer strands are twisted around the outer side of the inner strands in a face-contact manner, and the surface of each outer strand is coated with a polytetrafluoroethylene coating; a shaped steel wire is filled in the outer gap of each adjacent outer strand. The protective layer includes a corrosion-resistant layer and a wear-resistant layer. The corrosion-resistant layer is uniformly wrapped around the outer surface of the outer layer, and the wear-resistant layer is disposed on the corrosion-resistant layer. The inner strand includes an inner core and several outer fine steel wires spirally twisted around the inner core in line contact; the inner core includes an aramid fiber rope and several carbon fiber ropes and inner fine steel wires spirally twisted around the outer layer of the aramid fiber rope.

2. The composite steel wire rope for mine hoisting according to claim 1, characterized in that, A sound-absorbing layer is also provided between the outer layer 3 and the corrosion-resistant layer. The sound-absorbing layer includes a first rubber layer and a second rubber layer uniformly wrapped around the outside of the first rubber layer. A plurality of rubber support plates are provided between the first rubber layer and the second rubber layer. The two ends of the rubber support plates are respectively connected to the first rubber layer and the second rubber layer, and the space between the rubber support plates is filled with polyester fiber sound-absorbing cotton.

3. The composite steel wire rope for mine hoisting according to claim 2, characterized in that, The rubber support plate includes a first rubber support plate and a second rubber support plate. The first rubber support plate is evenly distributed between the first rubber layer and the second rubber layer, and both ends of the first rubber support plate along the width direction are fixedly connected to the first rubber layer and the second rubber layer, respectively. The second rubber support plate is respectively disposed between two adjacent first rubber support plates, and one end of each second rubber support plate along the width direction is connected to the end of the adjacent first rubber support plate near the first rubber plate, and the other end is connected to the end of another adjacent first rubber support plate near the second rubber plate. The polyester fiber sound-absorbing cotton is filled between the first rubber support plate and the second rubber support plate.

4. The composite steel wire rope for mine hoisting according to claim 1, characterized in that, The outer strand includes an outer core, several middle coarse steel wires spirally twisted in a surface-contact manner on the outer core, and an outer coarse steel wire spirally twisted in a surface-contact manner on the outside of the middle coarse steel wire; the outer core includes a core steel wire and several inner coarse steel wires spirally twisted in a surface-contact manner on the outside of the core steel wire.

5. The composite steel wire rope for mine hoisting according to claim 1, characterized in that, The filler strand includes a polyester fiber core and several filler steel wires that are uniformly twisted around the outside of the polyester fiber core in a face-to-face contact manner.

6. The composite steel wire rope for mine hoisting according to claim 1, characterized in that, A water-blocking yarn is also provided between the outer strand and the shaped steel wire.

7. A method for manufacturing a composite steel wire rope for mine hoisting, applicable to manufacturing the composite steel wire rope for mine hoisting as described in claim 1, characterized in that, include: S1. Fabrication of the composite rope core: Raw materials are selected in the following order by weight percentage: 40:15:5:10:4:2:2.5: nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant. The above raw materials are mixed and treated, and then melt-drawn to form filaments. Several of the filaments are twisted together to form a rope core strand. The rope core strand is then spirally twisted around the outside of a central strand made of aramid fiber in a line contact manner to form the composite rope core. S2. Composite rope core oil immersion: The composite rope core is dried under vacuum conditions for 1-1.5 hours, and then immersed in oil under vacuum pressure for 2-2.5 hours to obtain a composite rope core with high oil content. S3. Obtaining galvanized steel wire: High-carbon steel high-quality carbon wire rod is roughly drawn as a rough drawing billet, and the rough drawing billet is subjected to heat treatment and hot-dip galvanizing processes to obtain heat-treated galvanized steel wire, which is then drawn by a wire drawing machine to obtain galvanized steel wire of different specifications. S4. Twisting of the inner strand: Select aramid fiber rope, carbon fiber rope and galvanized steel wire of appropriate specifications; dry the aramid fiber rope and carbon fiber rope, compact them with a machine, heat and press them to solidify and form them, take several galvanized steel wires and carbon fiber ropes of the same specifications as the carbon fiber rope, arrange them alternately around an aramid fiber rope and spirally twist the aramid fiber rope to obtain the inner strand core; then select another specification of galvanized steel wire and spirally twist it around the inner strand core in a line contact manner to obtain the inner strand, and coat the outer side of the inner strand with a fluorinated graphite coating; S5. Twisting of filler strands and outer strands: Galvanized steel wires are evenly twisted into outer strands in a certain arrangement. Galvanized steel wires are spirally twisted in a face-contact manner around the outside of a polyester fiber core to form filler strands. The galvanized steel wires of both the outer strands and filler strands are made from round wires through molding and forging into irregularly shaped and regular steel wires to form compacted strands. A polytetrafluoroethylene coating is then applied to the outer layer of the outer strands. S6. Rope Assembly: The twisted composite core and 5 inner strands are arranged using a splitter and deformed by a pre-deformer. Then, the inner strands are twisted to the outside of the composite core using a wire pressing die. The 5 filler strands are evenly placed in the gap between two inner strands and twisted together. Then, 10 outer strands are twisted to the outside of the inner strands using a wire pressing die and compacted using a roller compactor. Next, 10 galvanized steel wires are evenly placed in the gap between two outer strands and twisted together. Finally, the roller compactor compacts the galvanized steel wires in the gaps to form shaped steel wires. Finally, the stress is eliminated by a pre-deformer to obtain the steel wire rope body without a protective layer. S7. Oiling the surface of the wire rope: The twisted wire rope body is pressed into molten grease for oiling using an immersion method. The immersion time is 1-1.5 hours. S8: Protective layer preparation: A corrosion-resistant layer and a wear-resistant layer 51 are sequentially applied to the outside of the oiled steel wire rope body to obtain the composite steel wire rope for mine hoisting. S9. Straightening and oil content detection of wire rope: The prepared wire rope is straightened to fully eliminate residual stress; then a portion of the wire rope is cut off with a hydraulic cutter as a sample for oil content detection to check whether the oil content of the prepared wire rope meets the preset requirements.

8. A method for manufacturing a composite steel wire rope for mine hoisting according to claim 7, characterized in that, The specific steps of S1 are as follows: S11. Raw materials selected in the following order by weight percentage: 40:15:5:10:4:2:2.5: Nylon fiber, sisal fiber, glass fiber, polyester fiber, plasticizer, stearic acid, and antioxidant. S12. Nylon fiber, sisal fiber, glass fiber and polyester fiber are respectively placed in a pulverizer for pulverization and then fed into a grinder for grinding. The ground raw materials are then put into a mixer for mixing to obtain a raw material mixture. S13. After adding a predetermined amount of plasticizer, stearic acid and antioxidant to the raw material mixture and mixing, the mixture is sent to a drying equipment for drying. The dried mixture is extruded through the screw of a twin-screw extruder and melted into a molten spinning solution. The molten spinning solution is then spun into filaments through a spinning assembly. S14. The filaments are cooled and cured by cooling air. The cured filaments are then wound into shape by a winding equipment to form composite rope core strands. S15. Select several prepared filaments and twist them together to form a core strand, and then spirally wrap the core strand around the outside of a central strand made of aramid fiber in a line-contact manner to form the composite core.

9. A method for manufacturing a composite steel wire rope for mine hoisting according to claim 7, characterized in that, The specific method for detecting the oil content of the wire rope in step S9 is as follows: S91: A portion of the prepared wire rope is cut off using a hydraulic cutter as a sample. After removing the protective layer, the wire rope body is separated into a core sample including a composite core and an inner strand core, and a strand sample including an inner strand, an outer strand, a filler strand, and a special-shaped wire. S92: Repeat the soaking and heating process multiple times on the strand sample, then dry it and weigh the dried strand sample. S93: After drying the rope core sample, repeat the soaking and heating operation multiple times, dry it a second time, and weigh the dried rope core sample. S94: Filter the soaking solution of the strand sample, obtain the filtered impurities, dry and cool the filtered impurities, and then weigh the filtered impurities. S95: Calculate the oil content of the wire rope to be tested by measuring the weight before and after the operation and the weight of filtered impurities based on the strand and core samples.

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