Special steel wire rope for hoist-lift vertical ship lift and its manufacturing method

Abstract

The application discloses a special steel wire rope for a hoist lifting type vertical ship lift and a manufacturing method thereof. The steel wire rope comprises a steel wire rope center strand, an inner layer strand is arranged on the outer periphery of the steel wire rope center strand, and a plurality of steel wire rope outer layer strands are uniformly arranged on the outer periphery of the inner layer strand. The manufacturing method specifically comprises the following steps: step 1, strand assembling and compaction are performed through a stranding machine and a compaction tool, and a steel wire rope center strand, a steel wire rope filling strand, a steel wire rope second inner layer strand and a steel wire rope outer layer strand are twisted; and step 2, one steel wire rope center strand, a plurality of steel wire rope filling strands, a plurality of steel wire rope second inner layer strands and a plurality of steel wire rope outer layer strands are twisted into the ship lift steel wire rope through a rope stranding machine once, and the rope type parallel twisted ship lift steel wire rope is obtained. The steel wire rope has an elastic modulus of more than 110 GPa, and an actual measured permanent elongation is less than or equal to 5 ‰, thereby meeting the performance requirements of the ship lift steel wire rope.

Description

Technical Field

[0001] This invention belongs to the field of wire rope technology, specifically relating to special wire ropes for winch-type vertical ship lifts, and also to a method for manufacturing special wire ropes for winch-type vertical ship lifts. Background Technology

[0002] Existing ship lifts are classified into three types: hydraulic, rack and pinion, and wire rope winch type. Among them, the wire rope winch type is the most widely used. Therefore, the wire rope, as one of the key components of the ship lift, is of paramount importance in terms of safety and reliability. Due to the special nature of its use and safety requirements, the wire ropes are numerous, subject to heavy loads, operate frequently, and typically have a service life of over 20 years, placing high demands on their performance. Currently, China is still in the research and development stage of domestic production. The 6-strand and 8-strand wire ropes using traditional structures and manufacturing processes cannot meet the requirements of large-tonnage ship lifts. This is mainly because the wire ropes for ship lifts must have a permanent elongation of less than or equal to 5‰, and the length deviation of paired ropes must be controlled within ±50mm, which cannot be met by existing wire rope structures and conventional production processes. Summary of the Invention

[0003] The purpose of this invention is to provide a special steel wire rope for winch-type vertical ship lifts, solving the problem that existing steel wire ropes cannot meet the performance requirements of steel wire ropes for ship lifts.

[0004] Another object of the present invention is to provide a method for manufacturing special steel wire ropes for winch-type vertical ship lifts.

[0005] The technical solution adopted in this invention is a special steel wire rope for a winch-type vertical ship lift, comprising a central strand of steel wire rope, an inner layer strand arranged on the outer circumference of the central strand, and a plurality of outer strands of steel wire rope evenly arranged on the outer circumference of the inner layer strand.

[0006] The invention is further characterized by: The inner strands include several first inner strands of wire rope evenly arranged along the outer circumference of the central strand of the wire rope, and several second outer strands of wire rope evenly arranged along the outer circumference of the circle formed by the several first inner strands of the wire rope. The space between the central strand of the wire rope and the several outer strands of the wire rope is filled with a solid polymer.

[0007] The wire rope core strand includes a first core wire, and several first intermediate layer wires are evenly arranged on the outer circumference of the first core wire. Several first outer layer wires are evenly arranged on the outer circumference of the circle formed by the several first core wires.

[0008] Each wire rope has a second center wire in its first inner strand, and several second outer wires are evenly arranged on the outer circumference of the second center wire. Each outermost strand of the wire rope includes a fifth central wire, and several fifth intermediate wires are evenly arranged around the outer circumference of the fifth central wire. Several fifth outermost wires are evenly arranged around the outer circumference of the circle formed by the several fifth intermediate wires. Each outer strand of the wire rope includes a fourth central wire. Several inner wires are evenly arranged around the outer circumference of the fourth central wire. Several secondary outer wires are evenly arranged around the outer circumference of the circle formed by the several inner wires. Several fourth outer wires are evenly arranged around the outer circumference of the circle formed by the several secondary outer wires.

[0009] The inner layer strands include several wire rope filler strands evenly arranged along the outer circumference of the central strand of the wire rope, and a second inner layer strand of wire rope is provided between each two adjacent wire rope filler strands.

[0010] The central strand of the wire rope includes a first central wire, and several first outer layer wires are evenly arranged on the outer circumference of the first central wire.

[0011] Each wire rope filler strand includes a sixth center wire, and several sixth outer layer wires are evenly arranged on the outer circumference of the sixth center wire; Each wire rope has a second inner strand including a third center wire, and several third intermediate layer wires are evenly arranged on the outer circumference of the third center wire. Several third outer layer wires are evenly arranged on the outer circumference of the circle formed by the several third intermediate layer wires. Each outer strand of the wire rope includes a fourth central wire. Several inner wires are evenly arranged around the outer circumference of the fourth central wire. Several secondary outer wires are evenly arranged around the outer circumference of the circle formed by the several inner wires. Several fourth outer wires are evenly arranged around the outer circumference of the circle formed by the several secondary outer wires.

[0012] The center strand, the first inner layer strand, and the filler strand of the wire rope are all twisted or compacted strands, while the second inner layer strand, the second outer layer strand, and the outer layer strand are all compacted strands.

[0013] The second technical solution adopted in this invention is a method for manufacturing special steel wire ropes for winch-type vertical ship lifts, the specific steps of which are as follows: Step 1: One first center wire, several first intermediate layer wires, and several first outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the center strand of the wire rope. One second center wire and several second outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the first inner layer strand of the wire rope. One fifth center wire, several fifth intermediate layer wires, and several fifth outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the second outer layer strand of the wire rope. One fourth center wire, several inner layer wires, several second outer layer wires, and several fourth outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand of the wire rope. Step 2: The center strand of one wire rope, several first inner strands of wire rope, and several second outer strands of wire rope are twisted together in one step by a rope twisting machine to obtain a rope-type parallel twisted steel core. Step 3: Fill solid polymer using either offline plastic coating or online plastic filling. The offline plastic coating process fills solid polymer before the rope-type parallel twisted steel core and the outer strand of the wire rope are twisted in Step 2, resulting in a star-shaped plastic-coated padding rope core. The online plastic filling process fills solid polymer during the process of obtaining the rope-type parallel twisted steel core and the outer strand of the wire rope in Step 2. Step 4: Several outer strands of steel wire rope and the star-shaped plastic-coated padding rope core obtained by the star-shaped spiral steel core plastic coating process are evenly twisted along the circumferential direction of the groove on the star-shaped plastic-coated padding rope core by a rope combining machine, so that the outer strand of each steel wire rope is evenly embedded into the corresponding groove to obtain the ship lift steel wire rope. The third technical solution adopted in this invention is a method for manufacturing special steel wire rope for winch-type vertical ship lifts, characterized by the following specific steps: Step 1: One first center wire and several first outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the center strand of the wire rope. One sixth center wire and several sixth outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the filler strand of the wire rope. One third center wire, several third intermediate layer wires, and several third outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the second inner layer strand of the wire rope. One fourth center wire, several inner layer wires, several secondary outer layer wires, and several fourth outer layer wires are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand of the wire rope. Step 2: The central strand of one wire rope, several filler strands of one wire rope, several second inner strands of one wire rope, and several outer strands of one wire rope are twisted together in one step by a rope twisting machine to obtain a parallel twisted rope for the ship lift.

[0014] The beneficial effects of this invention are as follows: The special steel wire rope for winch-type vertical ship lifts is delivered in the form of a single-headed or double-headed rigging, used with left and right twist pairs. The length of a single steel wire rope is no more than 400m. The structure adopts a single-layer strand steel wire rope with a parallel twisted steel core, or a parallel twisted steel wire rope. The parallel twisted steel core steel wire rope is filled with solid polymer as a liner, thereby improving the internal contact stress of the steel wire rope, improving the structural stability of the steel wire rope, avoiding internal corrosion, and improving the impact resistance, filling coefficient, breaking tensile strength, and safety factor of the steel wire rope. By rationally selecting the lay ratio and parameter design of the steel wire rope and steel core rope, the elongation of the inner and outer layers of the steel wire rope is consistent and the elongation rate is small. At the same time, the elastic modulus of the steel wire rope can reach more than 110GPa, and the measured permanent elongation rate is less than or equal to 5‰. Food-grade biodegradable lubricating grease is used, which improves the lubrication and anti-corrosion performance of the steel wire rope during use while considering environmental protection and not polluting drinking water sources, thus meeting the requirements of special steel wire ropes for winch-type vertical ship lifts. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the first structure of the special steel wire rope for the winch-type vertical ship lift of the present invention. Figure 2 This is a schematic diagram of the second structure of the special steel wire rope for the winch-type vertical ship lift of the present invention; Figure 3 This is a schematic diagram of the third structure of the special steel wire rope used in the winch-type vertical ship lift of the present invention. Figure 4 This is a schematic diagram of a single-opening rigging for the special steel wire rope used in the winch-type vertical ship lift of the present invention. Figure 5 This is a schematic diagram of a single-closed rigging for the special steel wire rope used in the winch-type vertical ship lift of the present invention. Figure 6 This is a schematic diagram of a double-opening rigging for the special steel wire rope used in the winch-type vertical ship lift of the present invention. Figure 7 This is a schematic diagram of the double-closed rigging of the special steel wire rope used in the winch-type vertical ship lift of the present invention.

[0016] In the diagram, 1. the center strand of the wire rope, 2. the first inner layer strand of the wire rope, 3. the second inner layer strand of the wire rope, 4. solid polymer, 5. the outer layer strand of the wire rope, 6. the second outer layer strand of the wire rope, and 7. the filler strand of the wire rope. 11. First central steel wire; 12. First intermediate layer steel wire; 13. First outer layer steel wire; 21. Second central steel wire; 22. Second outer steel wire; 31. Third central steel wire; 32. Third intermediate layer steel wire; 33. Third outer layer steel wire; 51. Fourth central steel wire; 52. Inner layer steel wire; 53. Second outer layer steel wire; 54. Fourth outer layer steel wire; 61. Fifth central steel wire; 62. Fifth intermediate layer steel wire; 63. Fifth outer layer steel wire; 71. Sixth central steel wire; 72. Sixth outer steel wire. Detailed Implementation

[0017] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0018] Example 1 The present invention relates to a special steel wire rope for a winch-type vertical ship lift, comprising a central strand 1, an inner layer strand on the outer circumference of the central strand 1, and a plurality of outer strands 5 uniformly arranged on the outer circumference of the inner layer strand. The inner strands and the central strand 1 together form a steel core, which is formed by parallel twisting of the rope. The plurality of outer strands 5 are twisted around the steel core in one operation.

[0019] The wire rope center strand 1 includes a first center wire 11, a plurality of first intermediate layer wires 12 are evenly arranged on the outer circumference of the first center wire 11, and a plurality of first outer layer wires 13 are evenly arranged on the outer circumference of the circle formed by the plurality of first center wires 11.

[0020] Each outer strand 5 of the wire rope includes a fourth central wire 51. Several inner wires 52 are evenly arranged around the outer circumference of the fourth central wire 51. Several secondary outer wires 53 are evenly arranged around the outer circumference of the circle formed by the several inner wires 52. Several fourth outer wires 54 are evenly arranged around the outer circumference of the circle formed by the several secondary outer wires 53.

[0021] The inner strands include several first inner strands 2 of wire rope evenly arranged along the outer circumference of the central strand 1 of the wire rope, and several second outer strands 6 of wire rope evenly arranged along the outer circumference of the circle formed by the several first inner strands 2 of the wire rope.

[0022] The central strand 1, several inner strands 2, and the secondary outer strands 6 of the wire rope are twisted together in one operation with equal lay pitch.

[0023] Each inner strand 2 of the wire rope includes a second center wire 21, and several outer strands 22 are evenly arranged on the outer circumference of the second center wire 21.

[0024] Each outermost strand 6 of the wire rope includes a fifth central wire 61, and several fifth intermediate layer wires 62 are evenly arranged on the outer circumference of the fifth central wire 61. Several fifth outer layer wires 63 are evenly arranged on the outer circumference of the circle formed by the several fifth intermediate layer wires 62.

[0025] A solid polymer is filled between the central strand 1 of the wire rope and several outer strands 5 of the wire rope.

[0026] The center strand 1 and the inner strand 2 of the wire rope are both twisted or compacted strands, while the secondary outer strand 6 and the outer strand 5 of the wire rope are both compacted strands.

[0027] The surfaces of the first central steel wire 11, the first intermediate layer steel wire 12, the first outer layer steel wire 13, the second central steel wire 21, the second outer layer steel wire 22, the fifth central steel wire 61, the fifth intermediate layer steel wire 62, the fifth outer layer steel wire 63, the fourth central steel wire 51, the inner layer steel wire 52, the second outer layer steel wire 53, and the fourth outer layer steel wire 54 are all coated with a rare earth aluminum alloy coating.

[0028] like Figure 4 and Figure 5 As shown, one end of the wire rope of the present invention is connected to a single-open sling or a single-closed sling.

[0029] like Figure 6 and Figure 7 As shown, both ends of the wire rope of the present invention are connected to a double-open sling or a double-closed sling.

[0030] Example 2 The manufacturing method of the special steel wire rope for the winch-type vertical ship lift in Example 1 includes the following specific steps: Step 1: One first central steel wire 11, several first intermediate layer steel wires 12, and several first outer layer steel wires 13 are stranded and compacted using a stranding machine and compaction equipment to form the central strand 1 of the wire rope. One second central steel wire 21 and several second outer layer steel wires 22 are stranded and compacted using a stranding machine and compaction equipment to form the first inner layer strand 2 of the wire rope. One fifth central steel wire 61, several fifth intermediate layer steel wires 62, and several fifth outer layer steel wires 63 are stranded and compacted using a stranding machine and compaction equipment to form the second outer layer strand 6 of the wire rope. One fourth central steel wire 51, several inner layer steel wires 52, several second outer layer steel wires 53, and several fourth outer layer steel wires 54 are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand 5 of the wire rope. Step 2: The center strand 1 of a steel wire rope, several first inner layer strands 2 of steel wire rope, and several second outer layer strands 6 of steel wire rope are twisted together in one step by a rope twisting machine to obtain a rope-type parallel twisted steel core. Step 3: Fill solid polymer using either offline plastic coating or online plastic filling. The offline plastic coating process fills solid polymer before the rope-type parallel twisted steel core and the outer strand of the steel wire rope are twisted together in Step 2, resulting in a star-shaped plastic-coated padding rope core. The online plastic filling process fills solid polymer during the process of obtaining the rope-type parallel twisted steel core and the outer strand of the steel wire rope in Step 2. Step 4: Several outer strands 5 of steel wire rope and star-shaped plastic-coated padding rope core obtained by star-shaped spiral steel core plastic coating process are evenly twisted along the circumferential direction of the groove on the star-shaped plastic-coated padding rope core by a rope combining machine, so that each outer strand 5 of steel wire rope is evenly embedded into the corresponding groove to obtain the ship lift steel wire rope.

[0031] Example 3 The present invention relates to a special steel wire rope for a winch-type vertical ship lift, comprising a central strand 1, an inner layer strand on the outer circumference of the central strand 1, and a plurality of outer strands 5 uniformly arranged on the outer circumference of the inner layer strand, which are parallel twisted steel wire ropes.

[0032] The wire rope center strand 1 includes a first center wire 11, and a number of first outer layer wires 13 are evenly arranged on the outer circumference of the first center wire 11.

[0033] Each outer strand 5 of the wire rope includes a fourth central wire 51. Several inner wires 52 are evenly arranged around the outer circumference of the fourth central wire 51. Several secondary outer wires 53 are evenly arranged around the outer circumference of the circle formed by the several inner wires 52. Several fourth outer wires 54 are evenly arranged around the outer circumference of the circle formed by the several secondary outer wires 53.

[0034] The inner layer includes several wire rope filler strands 7 evenly arranged along the outer circumference of the central wire rope strand 1, and a second inner layer strand 3 of wire rope is arranged between each two adjacent wire rope filler strands 7.

[0035] The wire rope center strand 1, several wire rope filler strands 7, the second inner layer strand 3, and the outer layer strand 5 are all twisted together at the same pitch in one operation.

[0036] Each wire rope filler strand 7 includes a sixth center wire 71, and several sixth outer layer wires 72 are evenly arranged on the outer circumference of the sixth center wire 71.

[0037] Each second inner strand 3 of the wire rope includes a third central wire 31, and several third intermediate layer wires 32 are evenly arranged on the outer circumference of the third central wire 31. Several third outer layer wires 33 are evenly arranged on the outer circumference of the circle formed by the several third intermediate layer wires 32.

[0038] The center strand 1 and the filler strand 7 of the wire rope are both twisted or compacted strands, and the second inner layer strand 3 and the outer layer strand 5 of the wire rope are both compacted strands.

[0039] The surfaces of the first central steel wire 11, the first outer steel wire 13, the sixth central steel wire 71, the sixth outer steel wire 72, the third central steel wire 31, the third intermediate steel wire 32, the third outer steel wire 33, the fourth central steel wire 51, the inner steel wire 52, the second outer steel wire 53, and the fourth outer steel wire 54 are all coated with a rare earth aluminum alloy coating.

[0040] like Figure 4 and Figure 5 As shown, one end of the wire rope of the present invention is connected to a single-open sling or a single-closed sling.

[0041] like Figure 6 and Figure 7 As shown, both ends of the wire rope of the present invention are connected to a double-open sling or a double-closed sling.

[0042] Example 4 The manufacturing method of the special steel wire rope for the winch-type vertical ship lift in Example 3 includes the following specific steps: Step 1: One first central steel wire 11 and several first outer layer steel wires 13 are stranded and compacted using a stranding machine and compaction equipment to form the central strand 1 of the wire rope. One sixth central steel wire 71 and several sixth outer layer steel wires 72 are stranded and compacted using a stranding machine and compaction equipment to form the filler strand 7 of the wire rope. One third central steel wire 31, several third intermediate layer steel wires 32, and several third outer layer steel wires 33 are stranded and compacted using a stranding machine and compaction equipment to form the second inner layer strand 3 of the wire rope. One fourth central steel wire 51, several inner layer steel wires 52, several secondary outer layer steel wires 53, and several fourth outer layer steel wires 54 are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand 5 of the wire rope. Step 2: The central strand 1 of the wire rope, several filler strands 7, several second inner strands 3 and several outer strands 5 of the wire rope are twisted together in one step by a rope-forming machine to obtain a parallel twisted wire rope for the ship lift.

[0043] Example 5 The special steel wire rope for the winch-type vertical ship lift of this invention has the following required parameters: D74.0mm, structure 10×K31WS-EPIWRC(K), minimum breaking tensile strength of 4600kN, strength grade of 1960MPa, diameter control deviation of 0~4.0%, diameter out-of-roundness control deviation of 0~1.5%, elastic modulus of 110GPa or above, and measured permanent elongation of less than or equal to 5‰.

[0044] The unfolding structure of the wire rope is as follows: 10×K(1-6-6+6-12) / EP[8×K(1-9-9)-8×(1-6)-1×(1-9-9)] like Figure 1As shown, it includes a wire rope center strand 1, an inner layer strand is provided on the outer circumference of the wire rope center strand 1, and 10 wire rope outer layer strands 5 are evenly provided on the outer circumference of the inner layer strand. The inner layer strand and the wire rope center strand 1 are twisted in parallel in a rope-like manner, and the 10 wire rope outer layer strands 5 are twisted around the inner layer strand in one go.

[0045] The wire rope center strand 1 includes a first center wire 11, nine first intermediate layer wires 12 are evenly arranged on the outer circumference of the first center wire 11, and nine first outer layer wires 13 are evenly arranged on the outer circumference of the circle formed by the several first center wires 11.

[0046] Each outer strand 5 of the wire rope includes a fourth central wire 51. Six inner wires 52 are evenly arranged around the outer circumference of the fourth central wire 51. Twelve secondary outer wires 53 are evenly arranged around the outer circumference of the circle formed by the seven inner wires 52. Twelve fourth outer wires 54 are evenly arranged around the outer circumference of the circle formed by the twelve secondary outer wires 53.

[0047] The inner layer includes eight inner steel wire rope strands 2 evenly arranged along the outer circumference of the central steel wire rope strand 1, and eight secondary outer steel wire rope strands 6 evenly arranged along the outer circumference of the circle formed by the eight inner steel wire rope strands 2.

[0048] The wire rope center strand 1, several wire rope first inner layer strands 2 and wire rope second outer layer strands 6 are twisted together in one go with equal lay pitch.

[0049] Each inner strand 2 of the wire rope includes a second central wire 21, and six second outer wires 22 are evenly arranged on the outer circumference of the second central wire 21. Each outermost strand 6 of the wire rope includes a fifth center wire 61, and nine fifth intermediate layer wires 62 are evenly arranged on the outer circumference of the fifth center wire 61. Nine fifth outer layer wires 63 are evenly arranged on the outer circumference of the circle formed by the nine fifth intermediate layer wires 62.

[0050] A solid polymer is filled between the central strand 1 of the wire rope and several outer strands 5 of the wire rope. The solid polymer is composed of ethylene propylene copolymer and anti-aging agent. By filling with solid polymer, the structural stability and impact resistance of the wire rope are improved. A pad is formed between the inner strand and the outer strand of the wire rope, which improves the contact between the two and reduces or eliminates stress.

[0051] The structure of the center strand 1 of the wire rope is a 1×19S twisted strand, the structure of the inner layer strand 2 of the wire rope is a 1×7 twisted strand, the structure of the second outer layer strand 6 of the wire rope is a 1×K19S compacted strand, and the structure of the outer layer strand 5 of the wire rope is a 1×K31WS compacted strand.

[0052] The surfaces of the first central steel wire 11, the first intermediate layer steel wire 12, the first outer layer steel wire 13, the second central steel wire 21, the second outer layer steel wire 22, the fifth central steel wire 61, the fifth intermediate layer steel wire 62, the fifth outer layer steel wire 63, the fourth central steel wire 51, the inner layer steel wire 52, the second outer layer steel wire 53, and the fourth outer layer steel wire 54 are all coated with a rare earth aluminum alloy coating to improve the adhesion and corrosion resistance of the coating.

[0053] In this embodiment, the total cross-sectional area A of the steel wire rope is 2968 mm². 2 The wire rope fill factor is 0.69, the design lay angle is 19.94°, the twist loss is taken as 0.789 based on the empirical coefficient K, and the strength grade Rr of the galvanized steel wire is 2060MPa. According to the theoretical formula for the minimum breaking tensile force of the wire rope, the following is obtained: F C。min =A﹒ K﹒ Rr / 1000=2968×0.789×2060 / 1000=4824kN In the formula: A represents the total cross-sectional area of ​​the steel wire rope, in mm. 2 K represents the empirical coefficient for twisting loss; Rr represents the strength grade of galvanized steel wire, in MPa.

[0054] Therefore, the theoretically calculated minimum breaking tensile force F of the D74.0mm ship lift wire rope is... C。min =4824kN, which is greater than the minimum breaking tensile strength of 4600kN required for steel wire rope, and meets the design requirements.

[0055] According to the theoretical formula for the equivalent elastic modulus of steel wire rope, we get: E2=E1﹒ f﹒ cosβ=210×0.69×cos(19.94°)=136GPa In the formula: E1 represents the elastic modulus parameter of ordinary carbon steel, which is taken as 210GPa; F represents the wire rope filling coefficient; β represents the twist angle of the outer strand of the wire rope in the wire rope, in °.

[0056] Therefore, the theoretically calculated equivalent elastic modulus of the D74.0mm ship lift wire rope is E2=136GPa, which is greater than the required elastic modulus of 110GPa, thus meeting the design requirements.

[0057] The method for preparing the special steel wire rope for the winch-type vertical ship lift in this embodiment is implemented according to the following steps: Step 1: One first central steel wire 11, nine first intermediate layer steel wires 12, and nine first outer layer steel wires 13 are stranded and compacted using a stranding machine and compaction equipment to form the central strand 1 of the wire rope. One second central steel wire 21 and six second outer layer steel wires 22 are stranded and compacted using a stranding machine and compaction equipment to form the first inner layer strand 2 of the wire rope. One fifth central steel wire 61, nine fifth intermediate layer steel wires 62, and nine fifth outer layer steel wires 63 are stranded and compacted using a stranding machine and compaction equipment to form the second outer layer strand 6 of the wire rope. One fourth central steel wire 51, six inner layer steel wires 52, twelve second outer layer steel wires 53, and twelve fourth outer layer steel wires 54 are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand 5 of the wire rope. Step 2: The central strand 1 of one steel wire rope, the first inner layer strand 2 of eight steel wire ropes, and the second outer layer strand 6 of eight steel wire ropes are twisted together in one step by a rope-making machine to obtain a rope-type parallel twisted steel core. Step 3: Fill solid polymer using either offline plastic coating or online plastic filling. The offline plastic coating process fills solid polymer before the rope-type parallel twisted steel core and the outer strand of the steel wire rope are twisted together in Step 2, resulting in a star-shaped plastic-coated padding rope core. The online plastic filling process fills solid polymer during the process of obtaining the rope-type parallel twisted steel core and the outer strand of the steel wire rope in Step 2. The offline coating process includes star-shaped spiral steel core coating process and conventional steel core coating process; The star-shaped spiral steel core is coated with polymer according to the star-shaped coating spiral head and method described in patent publication number CN118065165A, entitled "Star-shaped coating spiral head and method for preparing star-shaped coated padding rope core", to obtain a star-shaped coated padding rope core. In step 2, a rope-type parallel twisted steel core is obtained as the uncoated rope core. Conventional steel core plastic coating process is a standard technical method in this field; The online filling process is carried out according to the filling mold and production process described in the patent with publication number CN209412599U and patent name "A rotary filling mold for manufacturing filled steel wire rope". In step 2, the rope-type parallel twisted steel core is used as the steel core of the steel wire rope, and the outer strand 5 of the steel wire rope is used as the outer strand of the steel wire rope. Step 4: The outer strands 5 of the 10 steel wire ropes and the star-shaped plastic-coated padding rope core obtained by the star-shaped spiral steel core plastic coating process are evenly twisted along the circumferential direction of the groove on the star-shaped plastic-coated padding rope core by a rope combining machine, so that the outer strands 5 of each steel wire rope are evenly embedded into the corresponding groove to obtain the ship lift steel wire rope.

[0058] Step 5: Perform offline pre-tensioning on the obtained steel wire rope for the ship lift. The maximum pre-tensioning load is 40% of the minimum breaking tensile force. After pre-tensioning, use an extensometer to measure the elastic modulus of the steel wire rope and calculate the permanent elongation. Step 6: Perform wire rope cutting and casting for the ship lift. The length of the wire rope cutting for the ship lift is measured by laser infrared measurement to ensure the correct length deviation between the left and right twist pairs.

[0059] Example 6 The special steel wire rope for the winch-type vertical ship lift of this invention has the following required parameters: D64.0mm, structure 9×K36WS-EPIWRC(K), minimum breaking tensile strength of 3300kN, strength grade of 1960MPa, diameter control deviation of 0~4.0%, diameter out-of-roundness control deviation of 0~1.5%, elastic modulus of 110GPa or above, and measured permanent elongation of less than or equal to 5‰.

[0060] The unfolding structure of the wire rope is as follows: 9×K(1-7-7+7-14) / EP[6×K(1-9-9)-6×(1-6)-1×(1-9-9)] like Figure 2 As shown, it includes a wire rope center strand 1, an inner layer strand is provided on the outer circumference of the wire rope center strand 1, and nine outer layer strands 5 of wire rope are evenly provided on the outer circumference of the inner layer strand. The inner layer strand and the wire rope center strand 1 are twisted in parallel in a rope-like manner, and the nine outer layer strands 5 of wire rope are twisted around the inner layer strand in one go.

[0061] The wire rope center strand 1 includes a first center wire 11, nine first intermediate layer wires 12 are evenly arranged on the outer circumference of the first center wire 11, and nine first outer layer wires 13 are evenly arranged on the outer circumference of the circle formed by the several first center wires 11.

[0062] Each outer strand 5 of the wire rope includes a fourth central wire 51. Seven inner wires 52 are evenly arranged around the outer circumference of the fourth central wire 51. Fourteen secondary outer wires 53 are evenly arranged around the outer circumference of the circle formed by the seven inner wires 52. Fourteen fourth outer wires 54 are evenly arranged around the outer circumference of the circle formed by the fourteen secondary outer wires 53.

[0063] The inner layer includes six first inner layer strands 2 of wire rope evenly arranged along the outer circumference of the central strand 1 of the wire rope, and six second outer layer strands 6 of wire rope evenly arranged along the outer circumference of the circle formed by the six first inner layer strands 2 of the wire rope.

[0064] The wire rope center strand 1, several wire rope first inner layer strands 2 and wire rope second outer layer strands 6 are twisted together in one go with equal lay pitch.

[0065] Each inner strand 2 of the wire rope includes a second central wire 21, and six second outer wires 22 are evenly arranged on the outer circumference of the second central wire 21. Each outermost strand 6 of the wire rope includes a fifth center wire 61, and nine fifth intermediate layer wires 62 are evenly arranged on the outer circumference of the fifth center wire 61. Nine fifth outer layer wires 63 are evenly arranged on the outer circumference of the circle formed by the nine fifth intermediate layer wires 62.

[0066] A solid polymer is filled between the central strand 1 of the wire rope and several outer strands 5 of the wire rope. The solid polymer is composed of ethylene propylene copolymer and anti-aging agent. By filling with solid polymer, the structural stability and impact resistance of the wire rope are improved. A pad is formed between the inner strand and the outer strand of the wire rope, which improves the contact between the two and reduces or eliminates stress.

[0067] The structure of the center strand 1 of the wire rope is a 1×19S twisted strand, the structure of the first inner layer strand 2 of the wire rope is a 1×7 twisted strand, the structure of the second outer layer strand 6 of the wire rope is a 1×K19S compacted strand, and the structure of the outer layer strand 5 of the wire rope is a 1×K36WS compacted strand.

[0068] The surfaces of the first central steel wire 11, the first intermediate layer steel wire 12, the first outer layer steel wire 13, the second central steel wire 21, the second outer layer steel wire 22, the fifth central steel wire 61, the fifth intermediate layer steel wire 62, the fifth outer layer steel wire 63, the fourth central steel wire 51, the inner layer steel wire 52, the second outer layer steel wire 53, and the fourth outer layer steel wire 54 are all coated with a rare earth aluminum alloy coating to improve the adhesion and corrosion resistance of the coating.

[0069] In this embodiment, the total cross-sectional area of ​​the steel wire rope is 2188 mm². 2 The wire rope fill factor is 0.68, the design lay angle is 19.49°, the twist loss is taken as 0.789 based on empirical coefficient, and the galvanized steel wire strength grade is 1960MPa. According to the theoretical formula for the minimum breaking tensile force of the wire rope, the following is obtained: F C。min =A﹒ K﹒ Rr / 1000=2188×0.789×1960 / 1000=3384kN Therefore, the theoretically calculated minimum breaking tensile force F of the D74.0mm ship lift wire rope is... C。min =3384kN, which is greater than the minimum breaking tensile strength of the wire rope required to be 3300kN, and meets the design requirements.

[0070] According to the theoretical formula for the equivalent elastic modulus of steel wire rope, we get: E2=E1﹒ f﹒ cosβ=210×0.68×cos(19.49°)=134GPa Therefore, the theoretically calculated equivalent elastic modulus of the D64.0mm ship lift wire rope is E2=134GPa, which is greater than the required elastic modulus of 110GPa, thus meeting the design requirements.

[0071] The method for preparing the special steel wire rope for the winch-type vertical ship lift in this embodiment is implemented according to the following steps: Step 1: One first central steel wire 11, nine first intermediate layer steel wires 12, and nine first outer layer steel wires 13 are stranded and compacted using a stranding machine and compaction equipment to form the central strand 1 of the wire rope. One second central steel wire 21 and six second outer layer steel wires 22 are stranded and compacted using a stranding machine and compaction equipment to form the first inner layer strand 2 of the wire rope. One fifth central steel wire 61, nine fifth intermediate layer steel wires 62, and nine fifth outer layer steel wires 63 are stranded and compacted using a stranding machine and compaction equipment to form the second outer layer strand 6 of the wire rope. One fourth central steel wire 51, seven inner layer steel wires 52, fourteen second outer layer steel wires 53, and fourteen fourth outer layer steel wires 54 are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand 5 of the wire rope. Step 2: The central strand 1 of one steel wire rope, the first inner layer strand 2 of six steel wire ropes, and the second outer layer strand 6 of six steel wire ropes are twisted together in one step by a rope-making machine to obtain a rope-type parallel twisted steel core. Step 3: Fill solid polymer using either offline plastic coating or online plastic filling. The offline plastic coating process fills solid polymer before the rope-type parallel twisted steel core and the outer strand of the steel wire rope are twisted together in Step 2, resulting in a star-shaped plastic-coated padding rope core. The online plastic filling process fills solid polymer during the process of obtaining the rope-type parallel twisted steel core and the outer strand of the steel wire rope in Step 2. The offline coating process includes star-shaped spiral steel core coating process and conventional steel core coating process; The star-shaped spiral steel core is coated with polymer according to the star-shaped coating spiral head and method described in patent publication number CN118065165A, entitled "Star-shaped coating spiral head and method for preparing star-shaped coated padding rope core", to obtain a star-shaped coated padding rope core. In step 2, a rope-type parallel twisted steel core is obtained as the uncoated rope core. Conventional steel core plastic coating process is a standard technical method in this field; The online filling process is carried out according to the filling mold and production process described in the patent with publication number CN209412599U and patent name "A rotary filling mold for manufacturing filled steel wire rope". In step 2, the rope-type parallel twisted steel core is used as the steel core of the steel wire rope, and the outer strand 5 of the steel wire rope is used as the outer strand of the steel wire rope. Step 4: The nine outer strands 5 of the steel wire rope and the star-shaped plastic-coated padding rope core obtained by the star-shaped spiral steel core plastic coating process are evenly twisted along the circumferential direction of the groove on the star-shaped plastic-coated padding rope core by a rope combining machine, so that the outer strands 5 of each steel wire rope are evenly embedded into the corresponding groove to obtain the ship lift steel wire rope.

[0072] Step 5: Perform offline pre-tensioning on the obtained steel wire rope for the ship lift. The maximum pre-tensioning load is 40% of the minimum breaking tensile force. After pre-tensioning, use an extensometer to measure the elastic modulus of the steel wire rope and calculate the permanent elongation. Step 6: Perform wire rope cutting and casting for the ship lift. The length of the wire rope cutting for the ship lift is measured by laser infrared measurement to ensure the correct length deviation between the left and right twist pairs.

[0073] Example 7 The special steel wire rope for the winch-type vertical ship lift of this invention has the following required parameters: D50.0mm, structure 8×K36WS-PWRC(K), minimum breaking tensile strength of 2240kN, strength grade of 2160MPa, diameter control deviation of 0~4.0%, diameter out-of-roundness control deviation of 0~1.5%, elastic modulus of 110GPa or above, and measured permanent elongation of less than or equal to 5‰.

[0074] The unfolding structure of the wire rope is as follows: 8×K (1-7-7+7-14)-4×(1-6)F-4×K (1-9-9)-1×(1-6) like Figure 3 As shown, it includes a wire rope center strand 1, an inner layer strand is provided on the outer circumference of the wire rope center strand 1, and eight wire rope outer layer strands 5 are evenly provided on the outer circumference of the inner layer strand. The wire rope outer layer strands 5, the inner layer strands and the wire rope center strand 1 are made by parallel twisting of ropes.

[0075] The wire rope center strand 1 includes a first center wire 11, and six first outer layer wires 13 are evenly arranged on the outer circumference of the first center wire 11.

[0076] Each outer strand 5 of the wire rope includes a fourth central wire 51. Seven inner wires 52 are evenly arranged around the outer circumference of the fourth central wire 51. Fourteen secondary outer wires 53 are evenly arranged around the outer circumference of the circle formed by the seven inner wires 52. Fourteen fourth outer wires 54 are evenly arranged around the outer circumference of the circle formed by the fourteen secondary outer wires 53.

[0077] The inner strands include four second inner strands 3 of wire rope evenly arranged along the outer circumference of the central strand 1 of the wire rope. There are four wire rope filler strands 7 between each two adjacent second inner strands 3. The central strand 1 of the wire rope and the four second inner strands 2 of the wire rope are arranged in a quincunx pattern.

[0078] The wire rope center strand 1, several wire rope second inner layer strands 3, wire rope filler strands 7, and wire rope outer layer strands 5 are all twisted together at the same pitch in one operation.

[0079] Each wire rope filler strand 7 includes a sixth central wire 71, and six sixth outer layer wires 72 are evenly arranged on the outer circumference of the sixth central wire 71. Each second inner strand 3 of the wire rope includes a third center wire 31, and nine third intermediate layer wires 32 are evenly arranged on the outer circumference of the third center wire 31. Nine third outer layer wires 33 are evenly arranged on the outer circumference of the circle formed by the nine third intermediate layer wires 32.

[0080] The center strand 1 and the filler strand 7 of the wire rope are both twisted strands, while the second inner layer strand 3 and the outer layer strand 5 of the wire rope are both pressed strands.

[0081] The surfaces of the first central steel wire 11, the first outer steel wire 13, the sixth central steel wire 71, the sixth outer steel wire 72, the third central steel wire 31, the third intermediate steel wire 32, the third outer steel wire 33, the fourth central steel wire 51, the inner steel wire 52, the second outer steel wire 53, and the fourth outer steel wire 54 are all coated with a rare earth aluminum alloy coating.

[0082] In this embodiment, the total cross-sectional area of ​​the steel wire rope is 1325 mm². 2 The wire rope fill factor is 0.675, the design lay angle is 18.96°, the twist loss is taken as 0.789 based on empirical coefficient, and the galvanized steel wire strength grade is 2160MPa. According to the theoretical formula for the minimum breaking tensile force of the wire rope, the following is obtained: F C。min =A﹒ K﹒ Rr / 1000=1325×0.789×2160 / 1000=2258kN Therefore, the theoretically calculated minimum breaking strength F of the D50.0mm ship lift wire rope is... C。min =2258kN, which is greater than the minimum breaking tensile strength of the steel wire rope required to be 2240kN, and meets the design requirements.

[0083] According to the theoretical formula for the equivalent elastic modulus of steel wire rope, we get: E2=E1﹒ f﹒ cosβ=210×0.675×cos(18.96°)=134GPa Therefore, the theoretically calculated equivalent elastic modulus of the D64.0mm ship lift wire rope is E2=134GPa, which is greater than the required elastic modulus of 110GPa, thus meeting the design requirements.

[0084] The method for preparing the special steel wire rope for the winch-type vertical ship lift in this embodiment is implemented according to the following steps: Step 1: One first center wire 11 and six first outer layer wires 13 are stranded and compacted using a stranding machine and compaction equipment to form the center strand 1 of the wire rope. One sixth center wire 71 and six sixth outer layer wires 72 are stranded and compacted using a stranding machine and compaction equipment to form the filler strand 7 of the wire rope. One third center wire 31, nine third intermediate layer wires 32 and nine third outer layer wires 33 are stranded and compacted using a stranding machine and compaction equipment to form the second inner layer strand 3 of the wire rope. One fourth center wire 51, seven inner layer wires 52, fourteen secondary outer layer wires 53 and fourteen fourth outer layer wires 54 are stranded and compacted using a stranding machine and compaction equipment to form the outer layer strand 5 of the wire rope. Step 2: The central strand 1 of the steel wire rope, the second inner layer strands 3 of the four steel wire ropes, the filler strands 7 of the four steel wire ropes, and the outer layer strands 5 of the eight steel wire ropes are twisted together in one step by a rope twisting machine to obtain a parallel twisted steel wire rope for the ship lift. Step 3: Perform offline pre-tensioning on the obtained ship lift wire rope. The maximum pre-tensioning load is 40% of the minimum breaking tensile force. After pre-tensioning, use an extensometer to measure the elastic modulus of the wire rope and calculate the permanent elongation. Step 4: Cut and cast the obtained ship lift wire rope. The length of the cut wire rope is measured by laser infrared measurement to ensure that the left and right twists are used with the correct length.

Claims

1. A special steel wire rope for a winch-type vertical ship lift, characterized in that, It includes a wire rope center strand (1), an inner layer strand is provided on the outer circumference of the wire rope center strand (1), and several outer layer strands (5) are evenly provided on the outer circumference of the inner layer strand.

2. The special steel wire rope for a winch-type vertical ship lift according to claim 1, characterized in that, The inner strands include several first inner strands (2) of steel wire rope evenly arranged along the outer circumference of the center strand (1) of the steel wire rope, and several second outer strands (6) of steel wire rope evenly arranged along the outer circumference of the circle formed by the several first inner strands (2) of the steel wire rope. The space between the center strand (1) of the steel wire rope and the several outer strands (5) of the steel wire rope is filled with a solid polymer.

3. The special steel wire rope for a winch-type vertical ship lift according to claim 2, characterized in that, The steel wire rope center strand (1) includes a first center steel wire (11), and a number of first intermediate layer steel wires (12) are evenly arranged on the outer circumference of the first center steel wire (11), and a number of first outer layer steel wires (13) are evenly arranged on the outer circumference of the circle formed by the number of first center steel wires (11).

4. The special steel wire rope for a winch-type vertical ship lift according to claim 3, characterized in that, Each of the first inner strands (2) of the wire rope includes a second center wire (21), and a number of second outer wires (22) are evenly arranged on the outer circumference of the second center wire (21). Each of the outermost strands (6) of the wire rope includes a fifth center wire (61), and several fifth intermediate layer wires (62) are evenly arranged on the outer circumference of the fifth center wire (61), and several fifth outer layer wires (63) are evenly arranged on the outer circumference of the circle formed by the several fifth intermediate layer wires (62). Each outer strand (5) of the wire rope includes a fourth central wire (51), and several inner wires (52) are evenly arranged on the outer circumference of the fourth central wire (51). Several secondary outer wires (53) are evenly arranged on the outer circumference of the circle formed by the several inner wires (52), and several fourth outer wires (54) are evenly arranged on the outer circumference of the circle formed by the several secondary outer wires (53).

5. The special steel wire rope for a winch-type vertical ship lift according to claim 1, characterized in that, The inner layer includes several wire rope filler strands (7) evenly arranged along the outer circumference of the wire rope center strand (1), and a second inner layer strand (3) of wire rope is provided between each two adjacent wire rope filler strands (7).

6. The special steel wire rope for a winch-type vertical ship lift according to claim 5, characterized in that, The central strand (1) of the wire rope includes a first central wire (11), and several first outer layer wires (13) are evenly arranged on the outer circumference of the first central wire (11).

7. The special steel wire rope for a winch-type vertical ship lift according to claim 6, characterized in that, Each of the wire rope filler strands (7) includes a sixth center wire (71), and a number of sixth outer layer wires (72) are evenly arranged on the outer circumference of the sixth center wire (71). Each of the second inner strands (3) of the wire rope includes a third center wire (31), and a number of third intermediate layer wires (32) are evenly arranged on the outer circumference of the third center wire (31), and a number of third outer layer wires (33) are evenly arranged on the outer circumference of the circle formed by the number of third intermediate layer wires (32). Each outer strand (5) of the wire rope includes a fourth central wire (51), and several inner wires (52) are evenly arranged on the outer circumference of the fourth central wire (51). Several secondary outer wires (53) are evenly arranged on the outer circumference of the circle formed by the several inner wires (52), and several fourth outer wires (54) are evenly arranged on the outer circumference of the circle formed by the several secondary outer wires (53).

8. The special steel wire rope for a winch-type vertical ship lift according to claim 4 or 7, characterized in that, The wire rope center strand (1), the first inner layer strand (2), and the wire rope filler strand (7) are all twisted strands or compacted strands, while the wire rope second inner layer strand (3), the wire rope secondary outer layer strand (6), and the wire rope outer layer strand (5) are all compacted strands.

9. The method for manufacturing the special steel wire rope for a winch-type vertical ship lift according to claim 4, characterized in that, The specific steps are as follows: Step 1: Take one first central steel wire (11), several first intermediate layer steel wires (12), and several first outer layer steel wires (13) and use a stranding machine and compaction device to form a central strand (1) of the wire rope. Take one second central steel wire (21) and several second outer layer steel wires (22) and use a stranding machine and compaction device to form a first inner layer strand (2) of the wire rope. Take one fifth central steel wire (61), several fifth intermediate layer steel wires (62), and several fifth outer layer steel wires (63) and use a stranding machine and compaction device to form a second outer layer strand (6) of the wire rope. Take one fourth central steel wire (51), several inner layer steel wires (52), several second outer layer steel wires (53), and several fourth outer layer steel wires (54) and use a stranding machine and compaction device to form a third outer layer strand (5) of the wire rope. Step 2: The central strand (1) of one steel wire rope, several first inner layer strands (2) of several steel wire ropes, and several second outer layer strands (6) of steel wire ropes are twisted together in one go by a rope-making machine to obtain a rope-type parallel twisted steel core. Step 3: Fill solid polymer using an offline plastic coating process or an online plastic filling process. The offline plastic coating process fills solid polymer before the rope-type parallel twisted steel core and the outer strand (5) of the wire rope are twisted together in step 2 to obtain a star-shaped plastic-coated padding rope core. The online plastic filling process fills solid polymer during the process of twisting the rope-type parallel twisted steel core and the outer strand (5) of the wire rope in step 2. Step 4: Several outer strands (5) of steel wire rope and star-shaped plastic-coated padding rope core obtained by star-shaped spiral steel core plastic coating process are evenly twisted along the circumferential direction of the groove on the star-shaped plastic-coated padding rope core by a rope combining machine, and each outer strand (5) of steel wire rope is evenly embedded into the corresponding groove to obtain the ship lift steel wire rope.

10. The method for manufacturing the special steel wire rope for a winch-type vertical ship lift according to claim 7, characterized in that, The specific steps are as follows: Step 1: Take one first center wire (11) and several first outer layer wires (13) and use a stranding machine and compaction device to form a wire rope center strand (1). Take one sixth center wire (71) and several sixth outer layer wires (72) and use a stranding machine and compaction device to form a wire rope filler strand (7). Take one third center wire (31), several third intermediate layer wires (32), and several third outer layer wires (33) and use a stranding machine and compaction device to form a wire rope second inner layer strand (3). Take one fourth center wire (51), several inner layer wires (52), several secondary outer layer wires (53), and several fourth outer layer wires (54) and use a stranding machine and compaction device to form a wire rope outer layer strand (5). Step 2: The steel wire rope is twisted in one go by a rope twisting machine, consisting of one central strand (1), several filler strands (7), several second inner strands (3), and several outer strands (5) to obtain a parallel twisted steel wire rope for the ship lift.

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