A precision assembly system and assembly process for heavy steel wire rope suspension assemblies

Abstract

The application discloses a precision assembly system for counterweight steel wire rope suspension assembly, relates to the field of counterweight steel wire rope suspension assembly, and comprises a multi-specification universal integrated counterweight cross beam positioning tool, a gasket sorting and pre-assembly module, an FN wedge-shaped rope clamp multi-specification guiding cold-assembly tool and a door type integrated multi-point synchronous tension detection fine adjustment tool. The application also discloses a precision assembly process for counterweight steel wire rope suspension assembly, relates to the field of counterweight steel wire rope suspension assembly, and comprises incoming inspection and part pretreatment, counterweight frame cross beam tool positioning, pre-assembly gasket component positioning, suspension body classified diagonal bolt fastening, FN rope clamp and steel wire rope cold-assembly head making, steel wire rope pre-tensioning and stress relieving, multi-rope integrated tension precision adjustment, assembly final inspection, weight verification and trial operation acceptance. The application effectively combines the tool and the process, standardizes the whole-process precision, ensures operation quality and efficiency, reduces the requirement for the experience and skills of the operators, and saves labor and time.

Description

Technical Field

[0001] This application relates to the field of counterweight wire rope suspension assemblies, and in particular to a precision assembly system and assembly process for counterweight wire rope suspension assemblies. Background Technology

[0002] Elevators are a general term for vertical transportation tools and fixed lifting equipment within buildings. Different types of elevators are installed depending on the building's height, purpose, and passenger (or freight) volume. In terms of purpose, they mainly consist of passenger elevators, freight elevators, medical elevators, dumbwaiters, sightseeing elevators, vehicle elevators, ship elevators, and construction elevators. Passenger elevators are dedicated elevators for transporting passengers, requiring comprehensive safety facilities and a certain level of interior decoration. They are currently the most widely used type of elevator, and with the increasing prevalence of high-rise buildings (structures), the market application prospects for passenger elevators are extremely broad.

[0003] An elevator's function is vertical lifting within a building. Its working principle involves a traction rope connected to the car and counterweight at both ends, wound around the traction sheave and guide sheave. The traction motor, after speed reduction via a reducer, drives the traction sheave to rotate. The traction force generated by the friction between the traction rope and the traction sheave propels the car and counterweight up and down, achieving the transportation purpose. Therefore, an elevator mainly consists of a traction machine (winch), guiding system, safety devices, electric drive system, landing doors and car, signal control system, and counterweight device. The various functional components of the elevator are installed in the building's shaft and machine room, typically using wire rope friction drive. The wire rope passes around the traction sheave, with both ends connected to the car and counterweight (balance). The motor drives the traction sheave to raise and lower the car. As a vertical lifting device in a building, elevators have stringent requirements for safety, reliability, high transport efficiency, accurate leveling, and passenger comfort.

[0004] The counterweight system is essentially a structural component for balancing passenger elevators. It is an essential mechanism in passenger elevators, primarily consisting of a counterweight frame, counterweight blocks, counterweight wire ropes, counterweight buffers, and guide shoes. The counterweight frame has a rectangular frame structure, composed of an upper beam, a lower beam, and two side columns (vertical beams). The upper beam is located at the top of the counterweight frame, with a traction sheave in the middle, allowing for vertical lifting and lowering of the entire counterweight frame via the counterweight wire ropes. The lower beam... At the bottom of the counterweight frame, an external buffer can be installed to provide support and cushioning for the entire counterweight frame. Columns (vertical beams) are located on both sides, connecting the upper and lower beams respectively, forming a complete rectangular frame structure. Guide shoes are installed at the upper and lower ends of the outer sides of the columns to guide the counterweight frame during its vertical reciprocating movement within the elevator shaft. An oil reservoir is installed at the top of the columns to lubricate the guide shoes and shaft guide rails. The counterweight frame is installed by aligning the guide shoes with the guide rails from the top of the shaft and lowering it vertically to the bottom of the pit. The counterweight system is a major component of passenger elevators, and its operating status directly affects the overall use of the elevator. The counterweight frame is a key structural component of the counterweight system and a major quality control point in the manufacturing and installation of passenger elevators.

[0005] The essence of a counterweight is to provide dynamic balance, relatively balancing the weight of the car. In passenger elevator operation, it keeps the weight difference between the car and the counterweight within limits, ensuring normal traction transmission. Functionally, the counterweight is a component of the elevator traction system, reducing the power of the traction motor and the torque on the traction sheave and worm gear. The counterweight is installed in the elevator shaft and connected to the car via traction ropes and the traction sheave, maintaining balance between the car's weight and the effective load, thus reducing energy consumption and motor power loss. During elevator operation, the counterweight slides on the counterweight guide rails via four sets of counterweight guide shoes installed on both sides of the counterweight frame, providing balance during operation. Currently, there are various counterweight structures for passenger elevators, but regardless of the type, four guide shoes should be installed at the four corners of the counterweight to ensure vertical movement along the counterweight guide rails during elevator operation.

[0006] The counterweight wire rope suspension assembly is a key load-bearing component connecting the counterweight frame and the traction wire rope. It consists of a suspension base, FN wedge-shaped self-locking rope clamps, H-series fastening standard parts, HD-series graded adjusting shims (leveling shims, shock-absorbing shims, disc spring shims, etc.), and traction wire ropes of corresponding specifications. Holes are pre-drilled in the suspension base (usually nine holes, numbered 1# to 9#) to accommodate different specifications of wire ropes. Generally, the installation fixing points are 2#, 4#, 5#, 8#, and 9#, with the remaining holes sealed and left unused. The counterweight frame installation center distance C is divided into specifications of 710–933mm (FN=2.5), 934–1070mm (FN=2.7), and C≥1200mm. When C<1200mm, a maximum of 7 wire ropes can be installed; when C≥1200mm, a maximum of 9 wire ropes can be installed. Currently, the suspension assembly adopts a wedge-shaped cold-lock structure, abandoning the traditional Babbitt alloy cast rope head, and relying on HD gaskets to achieve multi-rope tension balance. The assembly quality directly affects elevator safety and the service life of the wire rope.

[0007] Currently, elevator parts manufacturers and maintenance units in China all use manual operations: visual inspection of incoming materials → manual marking and positioning with a tape measure → on-site selection of shims → tightening with a general-purpose wrench → bare rope clamps and hammering to fix the rope end → simple pre-tensioning of a single rope → adjusting the tension of each rope with a single-point tension gauge → secondary retesting after installation. The entire process lacks a complete set of specialized tooling, and assembly quality relies entirely on the workers' practical experience. Therefore, there are certain shortcomings in the industrialized assembly and production of counterweight steel wire rope suspension assemblies and in the maintenance operations within building elevator shafts, mainly involving five aspects: Firstly, the installation positioning accuracy is out of control: manual marking has large errors, there is no 5# reference integrated tooling, the base is installed crookedly, and the flange gap exceeds the standard; ordinary wrenches cannot accurately control the tightening torque of H05 (115±5N・m) and H08 (85±4N・m), and are prone to over-tightening and breaking threads, and under-tightening and loosening.

[0008] Secondly, there is a serious problem with the misuse and mismatch of shims: HD3 / HD6 / HD7 have similar appearances and are indistinguishable, so they are randomly used on site and multi-layered shims are pieced together to achieve non-standard thicknesses; there is no pre-sorting and pre-assembly, and the selection and matching of shims takes up a lot of time.

[0009] Thirdly, the FN rope clamp has significant manufacturing defects at the rope end: Without coaxial guidance, the wire rope is twisted during threading and the strands are misaligned, resulting in internal damage. There is no bending limit, the bending radius is generally less than 8 times the rope diameter, and the steel wire is prone to hidden breakage. Without fixed-point limiting, violent hammering can easily cause the rope clamp to crack, the wedge to deflect, and the clamping area to be insufficient. The length of the rope tail is visually controlled, and the size fluctuates between 20 and 60 mm, exceeding the national standard requirement of 25 to 45 mm. The tooling is of a single specification, and D13 / D16 / D19 are not interchangeable, leading to frequent tooling modifications.

[0010] Fourthly, the efficiency and accuracy of tension adjustment are low: single-point tension gauges are used for individual testing without synchronous testing fixtures, resulting in finished product tension generally exceeding ±5%, and single ropes experiencing long-term uneven wear and premature aging.

[0011] Fifthly, the process lacks standardization: the absence of a pre-tensioning and stress-relieving process for the wire rope results in large creep elongation of the wire rope in the later stages, requiring repeated on-site rope adjustments in a short period of time, leading to high maintenance costs.

[0012] A comprehensive online search revealed that patents related to "precision assembly of counterweight wire rope suspension assemblies" in the past decade mainly include: First, for heavy-duty positioning fixtures: CN215047903U (2021, Iris Corporation): Split L-shaped single-sided clamping counterweight frame tooling, only compatible with a single C size, without a multi-specification universal slot structure, unable to simultaneously lock all rope end mounting holes #2 / #4 / #5 / #8 / #9 at one time, does not have a #5 benchmark integrated positioning structure, only controls the frame's external dimensions, does not control the coaxial accuracy of the crossbeam rope holes.

[0013] Second, wedge-shaped rope clamp assembly fixtures: CN218201838U (2023, Shandong Iron and Steel): General wedge joint tooling for lifting equipment, only applicable to engineering machinery slings, without interchangeable D13 / D16 / D19 guide sleeves, without rope tail length limiting structure, and cannot be adapted to elevator-specific FN rope clamp installation. CN110054053B (2020, Beijing Huifeng Elevator): Single-sided clamp type rope clamp fixing tooling lacks a coaxial guide structure for the wire rope, cannot limit the bending radius of the wire rope, and cannot avoid the problem of rope twisting damage. CN211419232U (2020, Beijing United Tongli): U-shaped single-specification rope clamping fixture, which only fixes the wire rope and has no wedge block limit for the striking station.

[0014] Third, shim adjustment and tension tuning: CN209481013U (2019, Hitachi Elevator): Hydraulic dynamic rope tension compensation device, used for online leveling during elevator use, without assembly of front-end shims for sorting and pre-assembly of related structures. CN103303768A (2015, Fuzhou Hu Ailin): A dynamic compensation structure for hydraulic nuts involving the connection between wire rope and tapered sleeve, focusing on compensation at the user end and not involving gasket pretreatment in the production and assembly process; CN205045651U (2015, Jiangnan Jiajie): Nut stacked washer adjustment structure, only temporarily assembled on site, without color classification or pre-sealed design for different locations.

[0015] In summary, the assembly precision of the counterweight wire rope suspension assembly in passenger elevators is a critical process affecting the safety and comfort of elevator operation, whether in parts manufacturing or maintenance within the building shaft. A comprehensive process control system must be established, prioritizing safety, ensuring compliant processes, reliable tools, and qualified personnel, to minimize occupational health risks and improve operational efficiency while enhancing the company's core market competitiveness. Traditional assembly methods have five shortcomings. Furthermore, a comprehensive novelty search revealed that existing patents and papers in the industry primarily involve single, scattered tooling or minor process improvements. The industry lacks a complete assembly system integrating multi-specification positioning, shim pre-assembly, rope end limiting, and synchronous tension measurement, along with a closed-loop precision assembly process. This invention fills this technological gap in the field. Summary of the Invention

[0016] In order to improve the problems of poor positioning accuracy, mismatched and mixed use of shims, hidden damage in wire rope assembly, poor tension uniformity of multiple ropes, low assembly efficiency and lack of standardized process flow in the existing technology, this application provides a precision assembly system and assembly process for counterweight wire rope suspension assemblies.

[0017] Firstly, this application provides a technical solution for a precision assembly system of a counterweight wire rope suspension assembly, which employs the following approach: A precision assembly system for counterweight wire rope suspension assemblies, including Multi-specification universal integrated counterweight beam positioning fixture, used to position the suspension body on the counterweight frame; Gasket sorting and pre-assembly module is used to sort gaskets of different specifications by thickness, distinguish specifications, and pre-assemble them into sets according to assembly points. FN wedge rope clamps are multi-specification guide cold-fitting fixtures used for fixing rope head cone sleeves, guiding steel wire ropes, fixing rope tail lengths, cold-fitting wedge blocks, and installing rope clamps. The gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture is used to simultaneously detect the tension of multiple steel wire ropes and achieve fine-tuning of tension by adjusting the thickness of the shims.

[0018] By adopting the above technical solutions, the multi-specification universal integrated counterweight beam positioning fixture can establish a unified installation benchmark in the initial stage of assembly, reducing the deviation of the installation hole positions of the suspension body; the shim sorting and pre-assembly module can complete the thickness sorting and point configuration of shims before assembly, reducing the risk of shim mixing and mismatch; the FN wedge rope clamp multi-specification guiding cold assembly fixture can constrain the wire rope insertion direction, the exposed length of the rope tail, and the wedge hammering process, reducing hidden damage such as wire rope twisting and crushing; the gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture can synchronously detect and adjust the tension of multiple wire ropes, improving the consistency of force on multiple ropes. With the cooperation of the above fixtures, the assembly of the counterweight wire rope suspension assembly is transformed from relying on manual experience to standardized assembly based on fixture limits and parameter control, thereby improving assembly accuracy and assembly efficiency.

[0019] Optionally, the multi-specification universal integrated counterweight beam positioning fixture includes a fixture body with four limiting slots, each corresponding to a different counterweight installation center distance: C=710mm, C=933mm, C=1070mm, and C=1200mm. The fixture body also has five assembly positioning slots, corresponding to assembly points #2, #4, #5, #8, and #9, respectively.

[0020] By adopting the above technical solution, the four limiting slots can be adapted to counterweight frames with different installation center distances, so that the same set of positioning fixtures can be compatible with the assembly of counterweight wire rope suspension assemblies of various specifications; the five assembly positioning slots can correspond to different wire rope suspension installation points respectively, and mechanically limit the position of the suspension body or rope head mounting seat, thereby improving the positional consistency between each installation point.

[0021] Optionally, the gasket sorting and pre-assembly module includes a gasket thickness sorting table, a partitioned storage box, and a plastic sealing and packaging station. The gasket thickness sorting table is used to measure and sort the gasket thickness. The partitioned storage box is used to store the gaskets in partitions according to their specifications. The plastic sealing and packaging station packages the gaskets individually according to their corresponding assembly points based on the counterweight installation center distance and the number of steel wire ropes assembled.

[0022] By adopting the above technical solutions, the gasket thickness sorting station can detect and classify the actual thickness of the gaskets before assembly, reducing the height error of the suspension body caused by the deviation in gasket thickness; the partitioned storage box can store gaskets of different specifications independently, avoiding mixing of gaskets of different specifications; the plastic sealing and packaging station pre-assembles the gaskets required for each point into kits according to the counterweight frame specifications and the number of steel wire ropes, and marks the point number on the packaging, so that assembly personnel can directly take them according to the point on site, reducing the risk of misuse, omission and mixing of gaskets from the source, and improving assembly efficiency and consistency.

[0023] Optionally, the FN wedge-shaped rope clamp multi-specification guide cold fitting tooling includes a V-shaped clamp seat, the V-shaped clamp seat having a receiving cavity, a clamp plate threadedly connected to the V-shaped clamp seat, and multiple guide sleeves threadedly connected to the V-shaped clamp seat. The multiple guide sleeves are used to guide steel wire ropes of different diameters into the conical cavity of the rope head cone sleeve. Both side walls of the V-shaped clamp seat are threadedly connected to tightening bolts, which are used to support the side walls of the rope clamp cone sleeve.

[0024] By adopting the above technical solution, the V-shaped clamp can form a stable V-shaped support for the rope head cone sleeve, and press and fix it with the clamp plate. The support function of the side wall of the rope head cone sleeve is achieved by adjusting the protrusion length of the tightening bolt. The clamp plate and two tightening bolts can prevent the rope head cone sleeve from shaking or deflecting during the wire rope insertion and wedge installation. Multiple replaceable guide sleeves can be adapted and replaced according to different wire rope diameters, so that the wire rope enters the cone cavity of the rope head cone sleeve in a near coaxial state, effectively reducing the torsion, strand misalignment and local extrusion damage caused by the wire rope's skewed insertion, and improving the quality and consistency of rope head preparation.

[0025] Optionally, the FN wedge-shaped rope clamp multi-specification guide cold fitting tooling also includes a rubber hammer and a limit gauge on the side of the integrated V-shaped clamp seat. The limit gauge is used to temporarily fix the end of the wire rope. The rubber hammer is used to strike the wedge block inside the rope head cone sleeve so that the wedge block falls completely into the rope head cone sleeve.

[0026] By adopting the above technical solution, the limit gauge can provide a reference for the end of the wire rope after the wire rope passes through the rope head cone sleeve, avoiding the wire rope from shifting or moving after the rope is threaded and before the wedge is installed, thus ensuring the accurate threading length of the rope head; the wedge is struck with a rubber hammer so that the wedge can fall completely into the rope head cone sleeve and press the wire rope tightly.

[0027] Optionally, the multiple guide sleeves are respectively adapted to D13, D16 and D19 wire rope specifications; the minimum bending radius of the wire rope is not less than 8 times the nominal diameter of the wire rope; the limiting range of the limit gauge is 25mm to 45mm.

[0028] By adopting the above technical solutions, the three guide sleeves can be adapted to three common wire rope specifications, namely D13, D16 and D19, respectively, so that the same cold-fitting tooling can be adapted to different rope diameters by changing the guide sleeves; limiting the minimum bending radius of the wire rope to not less than 8 times the nominal diameter of the wire rope can avoid deformation, breakage or loosening of the outer wires of the wire rope due to small radius bending; setting the limit range of the rope tail length limit gauge to 25mm to 45mm can keep the exposed length of the rope tail within a safe and easy-to-inspect range, ensuring the consistency of the rope head preparation dimensions.

[0029] Optionally, the gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture includes a gantry frame, a placement platform, a fixing mechanism, a lateral offset mechanism, multiple tension sensors, and a data acquisition and display unit. The placement platform is located below the gantry frame, and the fixing mechanism is located on the placement platform for fixing the assembled counterweight frame and suspension body onto the placement platform. The lateral offset mechanism is installed on the gantry frame for pulling multiple steel wire ropes. Multiple tension sensors are installed at each steel wire rope detection point for detecting the tension value of each steel wire rope. The data acquisition and display unit is electrically connected to the multiple tension sensors for collecting the tension data of each steel wire rope. Leveling shims are added or removed at corresponding points based on the data collected by the data acquisition and display unit.

[0030] By adopting the above technical solutions, the fixing mechanism can stably fix the assembled counterweight frame and suspension assembly on the placement platform, providing a unified testing benchmark; the lateral offset mechanism can simultaneously apply the same lateral displacement load to all wire ropes, allowing all wire ropes to be compared under the same working conditions, eliminating measurement errors caused by inconsistent working conditions when testing each rope individually; multiple tension sensors independently measure at each wire rope installation point, and the data acquisition and display unit performs multi-channel synchronous acquisition and digital display, enabling operators to obtain the tension deviation values ​​of each rope in real time and intuitively, using the #5 reference rope as a reference; based on the collected tension data, the leveling shims at the corresponding points can be added, removed, or finely ground to achieve digital and precise leveling of multi-rope tension.

[0031] Secondly, this application provides a precision assembly process for counterweight wire rope suspension assemblies, employing the following technical solution: A precision assembly process for a counterweight wire rope suspension assembly, employing the assembly system provided in the first aspect to assemble the counterweight wire rope suspension assembly, includes the following steps: S1. Incoming material inspection and component pre-processing: Check the material model and drawing version, clean the anti-rust oil and impurities from the surface of the suspension body, bolts and wire ropes, check the center distance of the counterweight frame installation and the actual outer diameter of the wire rope, and isolate and scrap unqualified parts; at the same time, complete the classification and pre-sealing of all batches of gaskets at the gasket sorting table. S2. Counterweight frame crossbeam positioning fixture: Select the corresponding multi-specification universal integrated counterweight crossbeam positioning fixture according to the actual measured installation center distance of the counterweight frame, and fix it to the upper beam of the counterweight frame. Add rubber dust plugs to the unused installation holes and lock the assembly reference positions #2, #4, #5, #8, and #9. S3. Pre-installed gasket assembly: Remove the gasket plastic bag and lay the complete gasket assembly flat on the lower end face of the G02 / CO1 suspension body flange according to the marked points. S4. Tiered diagonal bolt fastening of the suspension body: After the suspension body base is in place, H05 and H08 are assembled in sections; two people tighten the bolts diagonally in three stages: 30% pre-tightening torque → 50% intermediate torque → 100% final tightening torque. S5, FN rope clamps and cold-installed wire rope heads: Use V-shaped clamps and clamps to fix the rope head cone sleeve. Replace the matching guide sleeve according to the size of the wire rope. The wire rope passes straight through the guide sleeve into the cone cavities on both sides of the rope head cone sleeve. The limit rubber hammer drives the wedge into the hole, and the limit gauge controls the length of the rope tail. S6. Wire rope pre-tensioning stress relief: Temporarily fix the upper end of the wire rope, apply a load of 1.2 times the self-weight of a single assembly with the tensioning fixture, and let it stand at room temperature for 4 hours to eliminate the residual stress from the rolling of the wire rope. S7. Multi-rope integrated tension precision adjustment: The tension of each wire rope is collected synchronously through the gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture. Taking the wire rope at point 5 as the reference, the leveling shims at the corresponding points are added or removed. For minor deviations, the thickness of the shims is corrected by grinding the shims with a grinding machine. After the adjustment is completed, all bolts are tightened to the standard torque. S8. Final inspection, weight verification and trial operation acceptance of the assembly: inspect the bolt tightening torque, gasket assembly status and rope clamp fixing status; calculate the theoretical weight using the original factory theoretical weight formula, and measure the assembly weight using an electronic scale; perform 50 trial runs of the whole machine under no-load → half-load → full-load conditions, and then stop the machine for a second re-inspection.

[0032] By adopting the above technical solution, this assembly process divides the assembly of the heavy-duty wire rope suspension assembly into continuous steps, including incoming material inspection, beam positioning, shim pre-installation, suspension body fastening, rope clamp cold-installation head making, pre-tensioning stress relief, tension adjustment, and final inspection and acceptance. This creates a fixed sequence and closed-loop control for the assembly process. Incoming material inspection can eliminate substandard parts in terms of size or condition at the source; beam tooling positioning can establish a unified assembly benchmark; shim pre-installation can reduce the risk of mismatch; graded diagonal bolt fastening can improve the installation stability of the suspension body; cold-installation head making of rope clamps can reduce wire rope damage; pre-tensioning stress relief can reduce creep elongation after commissioning; multi-rope tension adjustment can improve the uniformity of stress on each wire rope; and final inspection and trial operation acceptance can provide final confirmation of the assembly quality. This achieves standardized and precise assembly of the heavy-duty wire rope suspension assembly.

[0033] Optionally, in the incoming material inspection and component pretreatment steps, the dimensional tolerance of the center distance of the counterweight frame installation is controlled within ±1.0mm; the flatness of the suspension body flange is controlled within ≤0.08mm / 100mm; the outer diameter tolerance of the wire rope is controlled within ±0.2mm; after the gaskets are sorted, they are packaged in sets according to points 2#, 4#, 5#, 8#, and 9#, and the packaging bags are marked with the corresponding point numbers.

[0034] By adopting the above technical solutions, clear quantitative acceptance tolerances are set for three key incoming material indicators: the center distance of the counterweight frame installation, the flatness of the suspension body flange, and the outer diameter of the wire rope. This enables the identification and isolation of out-of-tolerance parts at the front end of assembly, preventing unqualified materials from flowing into the assembly process and causing subsequent rework. Gaskets are packaged in sets according to the assembly points and labeled with numbers, corresponding one-to-one with the points in subsequent processes. This eliminates the need for assembly personnel to measure and select gaskets online, further shortening the final assembly time.

[0035] Optionally, in the counterweight beam tooling positioning step, the coaxiality of each mounting hole is ≤0.5mm, and the dimensional tolerance of the center distance between adjacent holes is ±0.8mm.

[0036] By adopting the above technical solution, the geometric tolerance indicators that each installation hole should reach after the beam tooling positioning step is completed are clarified, providing a precise hole position reference for the subsequent suspension body placement and bolt tightening, and avoiding the base installation tilt or flange gap exceeding the tolerance due to the accumulation of hole position deviation.

[0037] Optionally, the FN rope clamp and the cold-installation head of the wire rope step include the following steps: S51. Pre-treatment of rope ends: Degrease and clean the predetermined length area of ​​the wire rope end, and shape and bend it through the wire rope bending limit frame so that the bending radius is not less than 8 times the nominal diameter of the wire rope. S52. Rope head cone sleeve positioning and locking: Clamp the original rope head cone sleeve of the corresponding specification into the V-shaped clamp, and fix and lock it with the clamp plate and the top bolt to keep the axis of the rope head cone sleeve coaxial with the axis of the corresponding guide sleeve. S53. Coaxial insertion of wire rope into conical cavity for shaping: The pre-treated wire rope is inserted straight into the inner cavity of the rope head conical sleeve through the guide sleeve, passes around the arc groove of the wedge block and exits from the bottom of the conical sleeve, and passes around the arc groove of the wedge block and exits from the bottom of the conical sleeve. S54. Rope end length limit setting: After the wire rope is passed out, the rope end abuts against the end face of the side limit gauge, and the wire rope extension is finely adjusted and fixed at 30±2mm. The rope end is temporarily fixed by the gauge locking piece to prevent it from retracting during the head-making process. S55. Rubber hammer evenly taps into the wedge: The rubber hammer vertically taps the upper surface of the wedge in three stages: 30% stroke → 60% stroke → 100% stroke, until the wedge is completely inserted into the rope head cone sleeve. S56. Tooling loosening and semi-finished product self-inspection: Loosen the V-shaped clamp, remove the rope end assembly, and check the wire rope for damage, wedge loosening, and rope tail size; ensure that the wire rope is free of pressure damage and broken wires, the wedges are not loose, and the rope tail size is compliant; disassemble and reassemble any unqualified parts.

[0038] By adopting the above technical solution, the traditional rope end-making process, which relies on workers' experience, is broken down into six standardized steps with a strict sequence. Each step corresponds to clear tooling constraints and quality inspection standards. Specifically, the pre-treatment process, through degreasing and bending limit, ensures the cleanliness of the wire rope and the minimum bending radius; the cone sleeve positioning and locking, and coaxial insertion, mechanically ensure the wire rope enters the cone cavity without twisting; the rope end length setting and repeated tapping of the wedge block ensure that the exposed dimensions of the rope end and the wedge block contact area meet the standards; and the final semi-finished product self-inspection forms a quality gate within the process, immediately disassembling and reassembling unqualified parts to prevent defects from flowing into the next process. This series of steps, in conjunction with cold-fitting tooling, achieves precision and non-destructive rope end preparation.

[0039] Optionally, in the final inspection, weight verification and trial operation acceptance steps of the assembly, the theoretical weight calculation formula is: M=(C-0.046)×65.5-4+4.7×FN(kg); where: C=center distance of counterweight frame installation (m), FN=actual number of steel wire ropes assembled; the deviation between the measured weight and the theoretical weight ≤3% is considered as qualified.

[0040] By adopting the above technical solution, a formula for calculating the theoretical weight of the assembly is provided for different specifications of counterweight frames and the number of wire ropes. By comparing the actual weight measured by the electronic scale with the theoretical weight calculated by the formula, the assembly integrity and counterweight balance coefficient can be quickly verified, avoiding excessive weight deviation due to missing or incorrect parts, and providing a quantitative basis for the final quality judgment of the assembly before leaving the factory.

[0041] In summary, this application includes at least one of the following beneficial technical effects: 1. The tooling and process are effectively combined, following the assembly principle of "tooling first, benchmark positioning, pre-assembly, and step-by-step parameter control". Standardized control of the entire process accuracy ensures the quality and efficiency of the operation, reduces the requirements for the experience and skills of the operators, reduces labor intensity, reduces occupational health risks, is safe and reliable, saves labor and time, and is practical and efficient. 2. Significantly improved assembly precision: The complete set of tooling limits and constrains the dimensions of each process, and standardizes and controls all parameters such as bolt torque, hole size, and rope head size. The tension of the wire rope is optimized from the traditional ±5% to ≤±3%, eliminating hidden damage such as wire rope twisting, broken wires, and rope clamp cracking. The overall service life of the wire rope is increased by more than 30%. 3. Improved production and assembly efficiency: Pre-installation of gaskets and multi-point synchronous tension detection reduce assembly time for single-piece assemblies by 45% to 55%, significantly reducing rework and repair workload and lowering labor costs. 4. Human error is greatly reduced: Gaskets are stored separately and sealed at different points to prevent misuse and mixing from the source. Full tooling limits the movement to avoid human operation deviations. It eliminates the reliance on the technical skills of senior assembly technicians. New employees can be trained and start working after a short period of time. 5. Reduced maintenance costs: The pre-tensioning stress relief process of the wire rope eliminates internal residual stress, resulting in a significant decrease in creep elongation after use. This reduces the frequency of secondary on-site tension adjustments after elevator delivery by 80%, greatly reducing after-sales maintenance expenses. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0043] Figure 1 This is a schematic diagram of the multi-specification universal integrated counterweight beam positioning fixture provided in the embodiment of the precision assembly system for counterweight wire rope suspension assembly of this application; Figure 2 This is a schematic diagram of the shim sorting pre-assembly module provided in the embodiment of the precision assembly system for heavy-duty steel wire rope suspension assembly of this application; Figure 3 This is a schematic diagram of the multi-specification guide cold assembly tooling for the FN wedge rope clamp provided in the embodiment of the precision assembly system for counterweight wire rope suspension assembly of this application; Figure 4 This is a schematic diagram of the gantry-type integrated multi-point synchronous tension detection and fine-tuning tooling provided in the embodiment of the precision assembly system for heavy-duty steel wire rope suspension assembly of this application; Figure 5 This is a simplified full assembly process flowchart provided in this application for an embodiment of a precision assembly system for a counterweight wire rope suspension assembly; Figure 6 This is a detailed full assembly process flowchart provided in this application for an embodiment of a precision assembly system for a counterweight wire rope suspension assembly; Figure 7 This is a simplified flowchart of the FN rope clamp and cold-installed wire rope head making steps provided in the embodiment of the precision assembly system for counterweight wire rope suspension assembly provided in this application; Figure 8 This is a detailed flowchart of the process for cold-assembling the FN rope clamp and the wire rope head, provided in the embodiment of the precision assembly system for counterweight wire rope suspension assembly of this application.

[0044] Reference numerals: 1. Multi-specification universal integrated counterweight beam positioning fixture; 2. Gasket sorting pre-assembly module; 3. FN wedge rope clamp multi-specification guide cold assembly fixture; 4. Gantry integrated multi-point synchronous tension detection and fine-tuning fixture; 11. Fixture body; 12. Limiting slot; 13. Assembly point #2; 14. Assembly point #4; 15. Assembly point #5; 16. Assembly point #8; 17. Assembly point #9; 21. Gasket thickness sorting table; 22. Partitioned storage box; 23. Plastic sealing and dispensing station; 31. V-shaped clamp; 32. Receiving cavity; 33. Clamping plate; 34. Guide sleeve; 35. Tightening bolt; 36. Rubber hammer; 37. Limiting gauge; 41. Gantry frame; 42. Placement table; 43. Fixing mechanism; 44. Lateral offset mechanism; 45. Tension sensor; 46. Data acquisition and display unit. Detailed Implementation

[0045] The following is in conjunction with the appendix Figure 1 - Appendix Figure 8 This application will be described in further detail.

[0046] A precision assembly system and assembly process for counterweight wire rope suspension assemblies is proposed, which addresses the pain points in the assembly of existing passenger elevator counterweight frame wire rope suspension assemblies. It consists of two parts: a modular precision assembly tooling system and a standardized directional assembly process, and is particularly suitable for counterweight frames of the CWT5 / CWT7 series with specifications D13 / D16 / D19.

[0047] In a first aspect, embodiments of this application disclose a precision assembly system for a counterweight wire rope suspension assembly.

[0048] A precision assembly system for counterweight wire rope suspension assemblies is divided into four independent functional modules, with one set of tooling compatible with four counterweight installation center distances of C=710 / 933 / 1070 / 1250mm. The assembly system includes a multi-specification universal integrated counterweight beam positioning tooling 1, a shim sorting pre-assembly module 2, a multi-specification FN wedge rope clamp guiding cold-assembly tooling 3, and a gantry-type integrated multi-point synchronous tension detection and fine-tuning tooling 4.

[0049] Reference Figure 1 A multi-specification universal integrated counterweight beam positioning fixture 1 is used to position the suspension body on the counterweight frame. Specifically, the multi-specification universal integrated counterweight beam positioning fixture 1 includes a fixture body 11, which is welded from Q235 steel. Four limiting slots 12 are machined inside the fixture body 11, with the spacing between each slot corresponding to four common counterweight installation center distance specifications: C=710mm, C=933mm, C=1070mm, and C≥1200mm.

[0050] Reference Figure 1Five assembly positioning slots are pre-installed on the main body of the tooling 11, which correspond to the assembly points 2#13, 4#14, 5#15, 8#16, and 9#17 on the crossbeam of the load-bearing frame, respectively.

[0051] Reference Figure 1 Assembly points 5# (15), 8# (16), and 9# (17) are all oblong holes. A baffle is welded to the side of the tooling body 11 near assembly point 2# (13), and another baffle is welded to the side of the tooling body 11 near the limiting slot 12. These two baffles achieve initial blocking of the counterweight beam position.

[0052] Furthermore, multiple rubber dust plugs can be provided to seal unused mounting holes on the counterweight frame crossbeams when a specific number of beams are assembled, preventing debris from entering and protecting the hole walls.

[0053] Furthermore, a 0.05mm go-stop flange clearance gauge can be provided to check the fit gap between the flange and the crossbeam after the suspension body is in place.

[0054] In use, the main body 11 of the fixture is directly snapped onto the outside of the upper beam of the counterweight frame. The limiting slot 12 engages with the end of the counterweight frame beam to achieve rapid positioning. All assembly holes can be locked in a single clamping operation, eliminating the need for repeated measurements and marking. The mechanical limiting of this fixture ensures that the coaxiality of each mounting hole is ≤0.5mm, and the dimensional tolerance of the center distance between adjacent holes is controlled within ±0.8mm.

[0055] Reference Figure 2 The gasket sorting and pre-assembly module 2 is used to sort gaskets of different specifications by thickness, differentiate their specifications, and pre-assemble them into complete sets according to their assembly points. Specifically, the gasket sorting and pre-assembly module 2 consists of three parts: a gasket thickness sorting table 21, a partitioned storage box 22, and a plastic sealing and dispensing station 23. Among them, the gasket thickness sorting table 21 integrates a high-precision digital display dial indicator with a resolution of not less than 0.001mm, which is used to measure the thickness of gaskets of various specifications such as HD3, HD4, HD6, HD7, and HD9 one by one, and to classify and screen them according to the actual thickness deviation.

[0056] The partitioned storage box 22 adopts a five-color identification partitioned storage structure: HD3 gaskets correspond to red, HD6 to blue, HD7 to yellow, HD4 to white, and HD9 to black, which visually distinguishes gaskets of different specifications that are similar in shape and prevents confusion.

[0057] At the plastic sealing and packaging station 23, based on the actual installation center distance C of the counterweight frame to be assembled and the number of steel wire ropes FN, the qualified gaskets that have been sorted are individually plastic sealed according to the required specifications and thicknesses of each point 2#, 4#, 5#, 8#, and 9#, and the corresponding point number is marked on the outside of the packaging bag.

[0058] Furthermore, the module can also be equipped with a small surface grinder. When the thickness of the shim needs to be slightly modified to meet the accuracy requirement of a total thickness error of ≤0.05mm for a single group, it is formed by single-piece precision grinding. It is strictly forbidden to stack multiple shims to make up non-standard thicknesses, so as to ensure the overall rigidity and thickness stability of the shim group.

[0059] Reference Figure 3 The FN wedge-shaped rope clamp multi-specification guide cold-fitting fixture 3 is used to fix the rope head cone sleeve, guide the steel wire rope, fix the rope tail length, cold-fit the wedge block, and install the rope clamp. Specifically, the FN wedge-shaped rope clamp multi-specification guide cold-fitting fixture 3 includes a V-shaped clamp seat 31, a clamping plate 33, multiple guide sleeves 34, a rubber hammer 36, and a limit gauge 37.

[0060] The V-shaped clamp 31 is made of Q235 material and has a receiving cavity 32. A clamping plate 33 is threadedly connected to one end of the top surface of the V-shaped clamp 31, and a guide sleeve 34 is threadedly connected to the other end. Multiple guide sleeves 34 are adapted to D13, D16, and D19 wire rope specifications respectively. Based on the actual specifications of the wire rope to be processed, a guide sleeve 34 with the corresponding inner diameter is selected and threaded onto the other end of the top surface of the V-shaped clamp 31. The coaxiality error between the inner hole of the guide sleeve 34 and the axis of the rope clamp cone sleeve after assembly can be controlled within ≤0.03mm.

[0061] The detachable connection between the clamping plate 33 and the V-shaped clamp 31 allows the rope head cone sleeve to be placed in the V-shaped clamp 31 and is vertically positioned. Additionally, tightening bolts 35 are threaded onto both side walls of the V-shaped clamp 31. By adjusting the protrusion length of the tightening bolts 35, they can support the side walls of the rope head cone sleeve, thus horizontally positioning it. The clamping plate 33 and the two tightening bolts 35 completely secure the cone sleeve within the V-shaped clamp 31, ensuring no movement of the rope head cone sleeve during subsequent operations.

[0062] The rope tail length limiting gauge 37 is integrated into the side of the V-shaped clamp 31, with a limiting length of 25mm to 45mm. It is used to temporarily fix the end of the wire rope and precisely control the exposed size of the rope end after the end is cut. The rubber hammer 36 is used to strike the wedge block to make it fully enter the rope clamp cone sleeve.

[0063] Furthermore, a wire rope bending limit frame can be installed, with arc grooves corresponding to three rope diameters: D13, D16, and D19. The radii of the arc grooves are R104mm (D13, 8×13=104), R128mm (D16, 8×16=128), and R152mm (D19, 8×19=152), respectively. This forces the wire rope to complete a shaping bend with a minimum bending radius of not less than 8 times the rope diameter before threading, thus physically preventing the hidden breakage of the wire rope caused by small-radius bending.

[0064] Reference Figure 4 The gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture 4 is used to simultaneously detect the tension of multiple wire ropes and achieve tension fine-tuning by adjusting the thickness of the shims. Specifically, the gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture 4 includes a gantry frame 41, a placement platform 42, a fixing mechanism 43, a lateral offset mechanism 44, multiple high-precision tension sensors 45, and a data acquisition and display unit 46. The placement platform 42 is located below the gantry frame 41, and the fixing mechanism 43 is installed on the placement platform 42 to securely clamp the assembled counterweight frame and its suspension assembly. The lateral offset mechanism 44 is installed on the crossbeam of the gantry frame 41, with an offset set to 150mm, to synchronously pull the assembled wire ropes, so that each wire rope completes tension detection under the same working conditions.

[0065] A high-precision tension sensor 45 is connected in series at each wire rope detection point, and the signal output of the sensor is connected in parallel to the data acquisition and display unit 46. The data acquisition and display unit 46 can collect and display the tension values ​​of all wire ropes in real time and synchronously, allowing operators to compare and analyze the values ​​with the tension value of the #5 reference rope.

[0066] Furthermore, the tooling is also equipped with a micro-shield precision grinding mechanism, which is used to perform precision grinding correction of HD leveling shims at designated points with a single thickness of ≤0.1mm based on tension detection data, so as to achieve digital and precise tension leveling.

[0067] In this embodiment, the fixing mechanism 43 can be a hydraulic device. A support frame is fixedly installed on the platform of the placement table 42, and six hydraulic cylinders are symmetrically arranged on the support frame. Each hydraulic cylinder is equipped with two connecting plates and an elastic element. The two ends of the elastic element are fixed to adjacent sides of the two connecting plates, and one of the connecting plates is fixed to the piston end of the hydraulic cylinder. This allows the downward pressing action of the hydraulic cylinder to have an adaptive elastic adjustment function, avoiding the impact on detection accuracy caused by local surface differences in clamping loosening.

[0068] After the assembled counterweight frame and suspension body are hoisted and placed on the placement platform 42, the piston of the hydraulic cylinder is extended to apply downward pressure to the counterweight frame, thereby fixing the counterweight frame on the placement platform 42.

[0069] The lateral offset mechanism 44 can be driven by an electric screw. The electric screw drive assembly includes a servo motor, a ball screw, a screw nut slide, and a load-bearing beam. The ball screw is rotatably mounted on the portal frame 41, and the screw nut slide can slide on the portal frame 41, with the screw nut slide threadedly connected to the ball screw. The servo motor is mounted on the portal frame 41, and its output end is fixed to the ball screw to drive its rotation. The screw nut slide is fixedly connected to the load-bearing beam, and the wire rope is connected to the load-bearing beam. By controlling the number of rotations of the servo motor, the load-bearing beam and the wire rope connected to it are ultimately driven to synchronously and uniformly offset laterally by 150mm, thereby achieving synchronous traction of the wire rope.

[0070] The implementation principle of a precision assembly system for counterweight wire rope suspension assemblies in this application embodiment is as follows: A multi-specification universal integrated counterweight beam positioning fixture 1 adapts to different installation center distances via four-position limit slots 12. A shim sorting pre-assembly module 2 completes shim thickness measurement, color-coded zoning, and point-based sealing at the assembly front end, preventing mismatched or mixed use. An FN wedge-shaped rope clamp multi-specification guide cold-assembly fixture 3 ensures coaxial insertion of the wire rope via replaceable guide sleeves 34, a bending limit frame forces a bending radius ≥ 8 times the rope diameter, limit gauges 37 precisely control the rope tail length, and a rubber hammer 36 evenly hammers the wedge into the limit position, achieving non-destructive cold-assembly of the rope head. A gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture 4 securely clamps the counterweight frame via a fixing mechanism 43, a lateral offset mechanism 44 drives all wire ropes to synchronously offset 150mm, tension sensors 45 at each point synchronously collect data, and digital precision leveling is performed using a #5 reference rope and a micro-shim fine grinding mechanism. The four modules work together to transform the traditional discrete operation that relies on human experience into a standardized assembly process based on tooling limits and parameter control.

[0071] Secondly, this application discloses a precision assembly process for counterweight wire rope suspension assemblies.

[0072] A precision assembly process for counterweight wire rope suspension assemblies, wherein the above-mentioned assembly system is used to assemble the counterweight wire rope suspension assemblies.

[0073] Reference Figure 5 and Figure 6 First, proceed with step S1: incoming material inspection and component pretreatment.

[0074] The incoming material inspection and parts pretreatment steps include: Operation: Verify the material model and drawing revisions; use a special environmentally friendly cleaning agent to clean the rust-preventive oil and impurities from the surface of the suspension body, bolts, and wire ropes; use precision calipers to measure the installation dimensions of the counterweight frame C and the actual outer diameter of the wire ropes; isolate and scrap unqualified parts; simultaneously, complete the classification and pre-sealing of all batches of gaskets at different locations on the gasket sorting table.

[0075] Precision control: C-dimensional tolerance ±1.0mm; suspension body flange flatness ≤0.08mm / 100mm; wire rope outer diameter tolerance ±0.2mm.

[0076] After completing step S1, which involves incoming material inspection and component pretreatment, proceed to step S2, which involves positioning the crossbeam fixture.

[0077] The positioning steps for the crossbeam fixture include: Operation: Select the corresponding gear positioning fixture according to the actual measured C dimension, fix it to the counterweight upper beam with buckles, add rubber dust plugs to the unused installation holes, and lock the assembly reference positions 2#, 4#, 5#, 8#, and 9#.

[0078] Precision control: the coaxiality of each mounting hole is ≤0.5mm, and the dimensional tolerance of the center distance between adjacent holes is ±0.8mm.

[0079] After completing step S2 and positioning the crossbeam fixture, proceed to step S3 to pre-install the gasket assembly.

[0080] The pre-installed gasket assembly placement step includes: Procedure: Remove the plastic seal of the gasket and lay the complete set of gaskets flat on the lower end face of the G02 / CO1 suspension body flange according to the marked points.

[0081] Precision control: The total thickness error of a single set of gaskets is ≤0.05mm, and the initial height difference of each base after pre-assembly is ≤1.5mm.

[0082] After completing step S3 and the pre-installed gasket assembly is in place, proceed to step S4 to tighten the diagonal bolts of the suspension body in stages.

[0083] The steps for tightening the diagonal bolts in the suspension body include: Operation: Position the CO1 / D13 and G02 / D16 bases, and assemble the H05 (M16 external hexagonal + HD4 shock-absorbing washer) and H08 (M16 internal hexagonal + HD9 disc spring washer) sections; tighten in three stages diagonally by two people: 30% pre-tightening torque → 50% intermediate torque → 100% final tightening torque; for mass production, pneumatic constant torque equipment can be used.

[0084] Precision control: H05 final tightening 115±5N・m, H08 final tightening 85±4N・m; flange and crossbeam fitting gap ≤0.05mm, base installation verticality ≤0.3°.

[0085] After completing step S4 and tightening the diagonal bolts of the suspension body, proceed to step S5, where the FN rope clamp and wire rope are cold-installed.

[0086] The steps for cold-installing the FN rope clamp and wire rope head include: Operation: Use the V-shaped tooling to clamp the corresponding specification FN rope clamp cone sleeve, replace with the matching specification guide sleeve 34, and insert the wire rope straight into the cone cavity along the guide sleeve 34. Use the limit rubber hammer 36 to drive in the wedge block, and use the limit gauge 37 to control the length of the rope tail.

[0087] Precision control: The exposed end of the wire rope is 25-45mm (±3mm); the contact area between the wedge and the inner surface of the cone sleeve is ≥85%; the wire rope is free from twisting and squeezing marks.

[0088] Reference Figure 7 and Figure 8 Furthermore, the process of cold-fitting the FN rope clamp and wire rope head is divided into 6 fixed steps, and the order of the steps cannot be changed: S51. Rope end pretreatment (pre-assembly).

[0089] Cut a 350mm section from the end of the wire rope, soak it in an environmentally friendly degreasing cleaner to remove oil and remove rust-preventive grease and dust from the surface of the wire rope. It is strictly forbidden to use a hard brush to grind the outer layer of steel wire. After pretreatment, place it in a bending limit frame and insert it into the corresponding arc groove to complete the shaping bend. The forced bending radius is 8×D (D is the nominal diameter of the wire rope).

[0090] Quality control: The bent arc fits the limiting groove perfectly, with no local bends smaller than 8D, and the steel wire has no extrusion dents.

[0091] S52, Rope head cone sleeve positioning and locking.

[0092] Based on the rope diameter model, install the corresponding FN original factory rope head cone sleeve in the V-shaped fixture, adjust the side tightening bolt 35 and the mounting clamp 33 to completely fix the cone sleeve in the V groove, ensuring that the axis of the rope head cone sleeve is coaxial with the axis of the guide sleeve 34, with a coaxial error ≤0.03mm; select the corresponding specification quick-insertion guide sleeve 34 and install it into the fixture hole.

[0093] Quality control: The rope head cone sleeve has no shaking and the guide sleeve 34 has no radial movement.

[0094] S53, the wire rope is coaxially inserted into the conical cavity for shaping.

[0095] The pre-treated wire rope is inserted straight into the inner cavity of the rope head cone sleeve from the inlet of the guide sleeve 34, passes around the arc groove of the wedge block, and exits from the bottom of the cone sleeve. The wire rope is in close contact with the inner hole of the guide sleeve 34 throughout the entire process, without twisting or lateral deviation. The wire rope is naturally relaxed during the rope threading process, and it is forbidden to forcibly pull or twist the strands.

[0096] Quality control: After the rope is threaded, there is no visible twisting or deformation in the wire rope, and the strands are not misaligned when inspected with a 10x magnifying glass.

[0097] S54, Rope tail length limit setting.

[0098] After the wire rope is passed through, the end of the rope abuts against the end face of the side limit gauge 37. The extension of the wire rope is finely adjusted and fixed at 30±2mm (preferably the middle value). The gauge locking piece temporarily fixes the end of the rope to prevent it from retracting during the head-making process.

[0099] Quality control: Exposed length 28-32mm, readjust if out of tolerance.

[0100] S55, the rubber hammer 36 at the limit position is evenly driven into the wedge block.

[0101] Align the wedge with the tooling limit and strike the center of the work station. Use a special rubber hammer 36 to strike the upper surface of the wedge vertically in three stages (30% stroke → 60% stroke → 100% stroke). Do not strike heavily or at an angle. After the wedge is fully in place, visually inspect it for any tilting.

[0102] Quality control: The contact area between the wedge block and the inner conical surface of the rope head cone sleeve is ≥88%, with no single-sided gaps.

[0103] S56. Tooling loosening, semi-finished product self-inspection.

[0104] Loosen the V-shaped clamp 31 locking bolt and clamp 33, remove the assembled rope end assembly, and remove the limit gauge 37 locking plate; use a 10x magnifying glass to check three places: 1. The wire rope has no crush damage or broken wires; 2. The wedge block is not loose; 3. The rope end size is compliant; disassemble and reassemble any unqualified parts.

[0105] Reference Figure 5 and Figure 6 After completing step S5, FN rope clamp and cold-installed wire rope head, proceed to step S6, wire rope pre-tensioning to relieve stress.

[0106] The pre-tensioning and stress-relief process of wire rope includes: Operation: Temporarily fix the upper end of the wire rope, apply a load of 1.2 times the self-weight of a single assembly using a tensioning fixture, and let it stand at room temperature for 4 hours to eliminate residual stress from the wire rope rolling process.

[0107] Precision control: unidirectional tensile deformation of the wire rope ≤ 0.08% of its total length, and the sag difference of the wire ropes in the same group after pre-tensioning and no-load is ≤ 3mm.

[0108] After completing step S6, pre-tensioning and stress relief of the wire rope, proceed to step S7, precise tension adjustment of the multi-rope integrated system.

[0109] The multi-rope integrated tension precision adjustment process includes: Operation: The integrated gantry tension fixture synchronously collects the tension of all wire ropes. Taking the wire rope at point 5 as the reference, the corresponding HD leveling shims are added or removed. For minor deviations, the thickness of the shims is corrected by precision grinding on a grinding machine. After the debugging is completed, all bolts are tightened to the standard torque.

[0110] Precision control: The relative average deviation of the tension of each rope is ≤ ±3%; the height difference of the top surface of each rope head is ≤ 2mm; the thickness of the shim is ≤ 0.1mm for a single adjustment.

[0111] After completing step S7, which involves precise adjustment of the tension of the multi-rope integrated system, proceed to step S8, which involves final inspection of the assembly, weight verification, and trial operation acceptance.

[0112] The final inspection, weight verification, and trial operation acceptance steps for the assembly include: Operation: Check the bolt tightening torque, gasket assembly status, and rope clamp fixing condition; calculate the theoretical weight using the original manufacturer's theoretical weight formula, and measure the assembly's self-weight using an electronic scale; perform a trial run of the entire machine 50 times under no-load, half-load, and full-load conditions, followed by a second inspection after shutdown.

[0113] Precision control: The bolt torque drop during the whole machine operation retest is ≤5%, and the tension index still meets the tolerance of ≤±3%.

[0114] Weight calculation formula: M=(C-0.046)×65.5-4+4.7×FN(kg). Where: C=center distance of counterweight frame installation (m), FN=actual number of steel wire ropes assembled, and the deviation between the measured weight and the theoretical weight is ≤3% to be considered qualified; Among them, 4.7×FN: The weight of a single rope end assembly (FN rope clamp + suspension base + complete set of H fasteners + HD gasket) is 4.7kg, and the weight of each FN rope end assembly is multiplied by 4.7. (C-0.046)×65.5: Weight of the counterweight frame beam body + the foundation of the mounting base; -4: Structural constant (original casting process weight reduction correction coefficient); Final M: Total weight (kg) of the entire CWT counterweight wire rope suspension assembly, used to verify the added weight of the counterweight block and the balance coefficient.

[0115] By following the above-mentioned work tools and assembly process, the precision assembly of counterweight steel wire rope suspension assemblies for passenger elevators of various specifications can be completed, thereby improving work efficiency and reducing the defect rate while meeting the technical requirements of special equipment.

[0116] The complete set of tooling limits and constrains the dimensions of each process, and standardizes and controls all parameters such as bolt torque, hole size, and rope head size. The tension of the wire rope is optimized from the traditional ±5% to ≤±3%, eliminating hidden damage such as wire rope twisting, broken wires, and rope clamp cracking. The overall service life of the wire rope is increased by more than 30%, and the assembly accuracy is greatly improved.

[0117] The implementation principle of the precision assembly process for counterweight wire rope suspension assembly in this application embodiment is as follows: The overall assembly process includes incoming material inspection and component pretreatment → counterweight frame beam tooling positioning → pre-installed shim assembly placement → graded diagonal bolt tightening of the suspension body → cold-installed head fabrication of FN rope clamps and wire ropes → wire rope pre-tensioning to relieve stress → multi-rope integrated tension precision adjustment → final assembly inspection, weight verification, and trial operation acceptance. These eight fixed processes follow the assembly principle of "tooling first, benchmark positioning, pre-installation, and step-by-step parameter control," standardizing and controlling the accuracy of the entire process. This effectively solves the five major defects of existing technologies: poor positioning, mismatched shims, wire rope damage, uneven tension, and low efficiency. It ensures work quality and efficiency, reduces the experience and skill requirements of operators, reduces labor intensity, lowers occupational health risks, and is safe, reliable, labor-saving, time-saving, practical, and efficient.

[0118] Unless otherwise defined, the technical or scientific terms used in this application shall have the ordinary meaning understood by one of ordinary skill in the art to which this application pertains. The terms "first," "second," "third," and similar terms used in this application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. The terms "an" or "a" and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms "comprising" or "including" and similar terms mean that the elements or objects preceding "comprising" or "including" encompass the elements or objects listed following "comprising" or "including" and their equivalents, and do not exclude other elements or objects. "Above," "below," "left," "right," etc., are used only to indicate relative positional relationships; when the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0119] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A precision assembly system for counterweight wire rope suspension assemblies, characterized in that: include Multi-specification universal integrated counterweight beam positioning fixture (1) is used to position the suspension body on the counterweight frame; Gasket sorting pre-assembly module (2) is used to sort gaskets of different specifications by thickness, distinguish specifications, and pre-assemble them into sets according to assembly points; The FN wedge-shaped rope clamp multi-specification guide cold-fitting fixture (3) is used to fix the rope head cone sleeve, guide the steel wire rope, fix the rope tail length, cold-fit the wedge block and install the rope clamp; the FN wedge-shaped rope clamp multi-specification guide cold-fitting fixture (3) includes a V-shaped clamp seat (31), the V-shaped clamp seat (31) is provided with a receiving cavity (32), the V-shaped clamp seat (31) is threaded with a clamp plate (33), the V-shaped clamp seat (31) is threaded with multiple guide sleeves (34), the multiple guide sleeves (34) are respectively used to guide steel wire ropes of different diameters to pass into the cone cavity of the rope head cone sleeve, and the two side walls of the V-shaped clamp seat (31) are threaded with tightening bolts (35), the tightening bolts (35) are used to support the side walls of the rope clamp cone sleeve; A gantry-type integrated multi-point synchronous tension detection and fine-tuning fixture (4) is used to synchronously detect the tension of multiple steel wire ropes and achieve tension fine-tuning by adjusting the thickness of the shims.

2. The precision assembly system for counterweight wire rope suspension assembly according to claim 1, characterized in that: The multi-specification universal integrated counterweight beam positioning fixture (1) includes a fixture body (11), on which four limiting slots (12) are provided. The four limiting slots (12) correspond to different counterweight installation center distances, C=710mm, C=933mm, C=1070mm, and C=1200mm respectively. The fixture body (11) also has five assembly positioning slots, which correspond to assembly point 2 (13), assembly point 4 (14), assembly point 5 (15), assembly point 8 (16), and assembly point 9 (17) respectively.

3. A precision assembly system for a counterweight wire rope suspension assembly according to claim 1, characterized in that: The gasket sorting and pre-assembly module (2) includes a gasket thickness sorting table (21), a partitioned storage box (22), and a plastic sealing and packaging station (23). The gasket thickness sorting table (21) is used to measure and sort the gasket thickness. The partitioned storage box (22) is used to store the gaskets in partitions according to their specifications. The plastic sealing and packaging station (23) packages the gaskets individually according to their corresponding assembly points based on the counterweight installation center distance and the number of steel wire ropes assembled.

4. A precision assembly system for a counterweight wire rope suspension assembly according to claim 1, characterized in that: The FN wedge-shaped rope clamp multi-specification guide cold fitting tool (3) also includes a rubber hammer (36) and a limit gauge (37) on the side of the integrated V-shaped clamp seat (31). The limit gauge (37) is used to temporarily fix the end of the wire rope. The rubber hammer (36) is used to strike the wedge block inside the rope head cone sleeve so that the wedge block falls completely into the rope head cone sleeve.

5. A precision assembly system for a counterweight wire rope suspension assembly according to claim 4, characterized in that: The multiple guide sleeves (34) are respectively adapted to D13, D16 and D19 wire rope specifications; the minimum bending radius of the wire rope is not less than 8 times the nominal diameter of the wire rope; the limiting range of the limiting gauge (37) is 25mm to 45mm.

6. A precision assembly system for a counterweight wire rope suspension assembly according to claim 1, characterized in that: The portal frame integrated multi-point synchronous tension detection and fine-tuning fixture (4) includes a portal frame (41), a placement platform (42), a fixing mechanism (43), a lateral offset mechanism (44), multiple tension sensors (45), and a data acquisition and display unit (46). The placement platform (42) is located below the portal frame (41), and the fixing mechanism (43) is located on the placement platform (42) for fixing the assembled counterweight frame and suspension body on the placement platform (42). The lateral offset mechanism (44) is installed on the portal frame (41) for pulling multiple steel wire ropes. Multiple tension sensors (45) are installed at each wire rope detection point to detect the tension value of each wire rope; The data acquisition and display unit (46) is electrically connected to multiple tension sensors (45) to collect tension data of each wire rope; the corresponding leveling shims are added or removed according to the data collected by the data acquisition and display unit (46).

7. A precision assembly process for a counterweight wire rope suspension assembly, comprising assembling the counterweight wire rope suspension assembly using the assembly system described in any one of claims 1-6, characterized in that: Includes the following steps: S1. Incoming material inspection and component pre-processing: Check the material model and drawing version, clean the anti-rust oil and impurities from the surface of the suspension body, bolts and wire ropes, check the center distance of the counterweight frame installation and the actual outer diameter of the wire rope, and isolate and scrap unqualified parts; at the same time, complete the classification and pre-sealing of all batches of gaskets at the gasket sorting table. S2. Counterweight frame beam positioning fixture: Select the corresponding multi-specification universal integrated counterweight beam positioning fixture (1) according to the actual measured installation center distance of the counterweight frame, and fix it to the upper beam of the counterweight frame. Add rubber dust plugs to the unused installation holes and lock the assembly reference positions of #2, #4, #5, #8, and #9. S3. Pre-installed gasket assembly: Remove the gasket plastic bag and lay the complete gasket assembly flat on the lower end face of the G02 / CO1 suspension body flange according to the marked points. S4. Tiered diagonal bolt fastening of the suspension body: After the suspension body base is in place, H05 and H08 are assembled in sections; two people tighten the bolts diagonally in three stages: 30% pre-tightening torque → 50% intermediate torque → 100% final tightening torque. S5, FN rope clamp and cold-installed wire rope head: Use V-shaped clamp (31) and clamp plate (33) to fix the rope head cone sleeve. Replace the matching guide sleeve (34) according to the size of the wire rope. The wire rope passes straight through the cone cavity on both sides of the rope head cone sleeve along the guide sleeve (34). The limiting rubber hammer (36) drives the wedge into the hole. The limiting gauge (37) controls the length of the rope tail. S6. Wire rope pre-tensioning stress relief: Temporarily fix the upper end of the wire rope, apply a load of 1.2 times the self-weight of a single assembly with the tensioning fixture, and let it stand at room temperature for 4 hours to eliminate the residual stress from the rolling of the wire rope. S7. Multi-rope integrated tension precision adjustment: The tension of each wire rope is collected synchronously through the gantry-type integrated multi-point synchronous tension detection and fine adjustment tool (4). Taking the wire rope at point 5 as the benchmark, the leveling shims at the corresponding points are added or removed. For minor deviations, the thickness of the shims is corrected by grinding the shims with a grinding machine. After the adjustment is completed, all bolts are tightened to the standard torque. S8. Final inspection, weight verification and trial operation acceptance of the assembly: inspect the bolt tightening torque, gasket assembly status and rope clamp fixing status; calculate the theoretical weight using the original factory theoretical weight formula, and measure the assembly weight using an electronic scale; perform 50 trial runs of the whole machine under no-load → half-load → full-load conditions, and then stop the machine for a second re-inspection.

8. The precision assembly process for a counterweight wire rope suspension assembly according to claim 7, characterized in that: In the incoming material inspection and component pretreatment steps, the dimensional tolerance of the center distance of the counterweight frame installation is controlled within ±1.0mm; the flatness of the suspension body flange is controlled within ≤0.08mm / 100mm; the outer diameter tolerance of the wire rope is controlled within ±0.2mm; after sorting, the gaskets are packaged in sets according to points 2#, 4#, 5#, 8#, and 9#, and the packaging bags are marked with the corresponding point numbers.

9. A precision assembly process for a counterweight wire rope suspension assembly according to claim 7, characterized in that: In the positioning step of the counterweight beam tooling, the coaxiality of each mounting hole is ≤0.5mm, and the dimensional tolerance of the center distance between adjacent holes is ±0.8mm.

10. A precision assembly process for a counterweight wire rope suspension assembly according to claim 7, characterized in that: The steps for cold-fitting the FN rope clamp and the wire rope head include the following: S51. Pre-treatment of rope ends: Degrease and clean the predetermined length area of ​​the wire rope end, and shape and bend it through the wire rope bending limit frame so that the bending radius is not less than 8 times the nominal diameter of the wire rope. S52, Rope head cone sleeve positioning and locking: clamp the original rope head cone sleeve of the corresponding specification in the V-shaped clamp (31), and fix and lock it by the clamp plate (33) and the top bolt (35) so that the axis of the rope head cone sleeve and the axis of the corresponding guide sleeve (34) remain coaxial; S53. Steel wire rope coaxially inserted into the cone cavity for shaping: The pre-treated steel wire rope is straight inserted into the inner cavity of the rope head cone sleeve through the guide sleeve (34), passes around the wedge block arc groove and then passes out from the bottom of the cone sleeve, and passes around the wedge block arc groove and then passes out from the bottom of the cone sleeve. S54, Rope tail length limit setting: After the wire rope is passed out, the end of the rope is against the end face of the side limit gauge (37), and the wire rope extension is finely adjusted and fixed at 30±2mm. The rope tail is temporarily fixed by the gauge locking piece to prevent it from shrinking back during the head making process. S55. Rubber hammer (36) evenly taps into the wedge: Rubber hammer (36) vertically taps the upper surface of the wedge in three stages: 30% stroke → 60% stroke → 100% stroke, so that the wedge falls completely into the rope head cone sleeve. S56. Tooling loosening and semi-finished product self-inspection: Loosen the V-shaped clamp (31), remove the rope end assembly, and check the wire rope damage, wedge loosening and rope tail size status; ensure that the wire rope is free from pressure damage and broken wires, the wedge is not loose, and the rope tail size is compliant; disassemble and reassemble unqualified parts.

11. A precision assembly process for a counterweight wire rope suspension assembly according to claim 7, characterized in that: In the final inspection, weight verification and trial operation acceptance steps of the assembly, the theoretical weight calculation formula is: M=(C-0.046)×65.5-4+4.7×FN(kg); where: C=center distance of counterweight frame installation (m), FN=actual number of steel wire ropes assembled; the deviation between the measured weight and the theoretical weight ≤3% is considered as qualified.

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