Color-Coded Multilayer Resin Core for Elevator Wire Rope Wear Detection
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Solution Overview
Problem
Conventional running wire ropes used in elevator rigging face challenges in accurately measuring the diameter, which is crucial for timely replacement to ensure safety, as existing methods require stopping the machine and are time-consuming, limiting detection accuracy.
Innovation Solution
A running wire rope with a multilayer resin core formed by different resin materials and colors, where the outer layers have higher wear resistance and are lighter, allowing for visual inspection of diameter changes through powder generation, facilitating timely replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement methods (Vernier calipers) are used to measure rope diameter, then measurement can be performed, but the machine must be stopped and multiple portions measured, consuming significant time and reducing productivity
Solution Approach 1:
The patent applies color coding to different resin layers in the core member, with each layer having a distinct color. As the rope wears and resin turns to powder, the color changes visible on the rope surface indicate the extent of wear and remaining diameter thickness. This allows operators to assess rope condition visually without stopping the machine or using measurement tools, resolving the contradiction between measurement accuracy and productivity.
2Measurement precision
If the number of measured portions is increased to improve detection accuracy, then measurement accuracy improves, but the time available for measurement decreases because the machine must be stopped
Solution Approach 1:
The color-coded resin layers provide continuous visual information about rope wear across the entire length of the rope. Operators can quickly scan multiple portions simultaneously by visual inspection rather than sequentially measuring each portion with calipers, thereby improving detection accuracy across multiple locations while minimizing time loss.
Solution Approach 2:
The rope itself provides measurement information through the visual color changes of the resin layers as they wear away. The rope structure serves its own inspection function, eliminating the need for external measurement tools and procedures that consume time.
3Strength
If a single-layer resin core is used, then the structure is simple, but wear resistance is insufficient and cost-effective high performance cannot be achieved
Solution Approach 1:
The patent uses a composite multi-layer resin structure where each layer can have different material compositions optimized for specific functions. The outer layers can be formulated for maximum wear resistance while inner layers provide structural support. This composite approach achieves high wear resistance and performance while managing cost effectiveness, accepting increased structural complexity as necessary for improved durability.
Solution Approach 2:
Different resin layers are assigned different material properties and colors based on their specific functional requirements. Outer layers experience more wear and are optimized for wear resistance with appropriate material composition and color coding, while inner layers have different requirements. This local optimization achieves high overall performance without unnecessary complexity throughout the entire structure.
Data Source
Figure 1~2
Figure 3
AI summary
To provide a running wire rope having excellent performance and being capable of improve facilitating measurement of a state of a diameter of a rope to derive improvement of safety. A running wire rope 1 is formed by twisting a plurality of strands 2 around a resin core 3 served as a resin core member. The resin core 3 is formed by a plurality of resin layers of a first resin layer 4 and a second resin layer 5. Resin materials of the first resin layer 4 and the second resin layer 5 adjacent to each other are different, or alternatively colors of the layers adjacent to each other are different.