Resin Spacer Wire Rope for Crane Wear Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing wire ropes for running wires in cranes suffer from high wear and breakage due to metal contact between strands and sheaves, leading to reduced fatigue resistance and service life, with previous solutions either failing to adequately address these issues or increasing costs and complexity.
Innovation Solution
A wire rope design featuring a core rope with a resin coating layer and resin spacers interposed between side strands, where the resin spacer extends between outer layer wires, preventing metal contact and constraining wire movement, thereby reducing breakage and elongation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If metal contact is avoided between strands and core rope by using resin coating, then wear between strands and core rope is reduced, but wear between strands and sheave cannot be avoided
Solution Approach 1:
A resin spacer is introduced as an intermediary component between the side strands and the core rope. This spacer prevents direct metal-to-metal contact while allowing the rope to maintain its structural integrity and fatigue resistance. The resin material acts as a mediator that eliminates harmful friction and wear between moving parts.
Solution Approach 2:
The invention uses composite material construction by combining metal wires with resin components. The resin spacer and resin coating create a composite structure that integrates the strength of metal with the wear-resistant properties of resin, solving both wear and fatigue resistance requirements simultaneously.
2Object-affected harmful factors
If a resin spacer is provided between side strands with wedge-like shape reaching center, then metal contact is avoided, but effective sectional area is reduced making it difficult to use for high breaking load applications
Solution Approach 1:
The resin spacer is designed with non-uniform thickness, being thicker at the base end and thinner toward the front end. This local quality variation allows the spacer to provide maximum wear protection where needed (between strands) while minimizing impact on the rope's effective sectional area and breaking load capacity.
Solution Approach 2:
The resin spacer is positioned to extend partially between the strands rather than completely filling the space. This partial action approach provides sufficient wear protection while avoiding excessive reduction of the effective metallic cross-section that would compromise breaking load.
3Stability of the object's composition
If reinforcement core is provided for filling material between strands, then filling material stability is improved, but special equipment is needed for fabrication at increased cost
Solution Approach 1:
The resin spacer is designed to be self-supporting through its own structural geometry (thick base end, thin front end) rather than requiring an internal reinforcement core. The spacer's shape provides inherent stability during installation and service, eliminating the need for additional reinforcement structures and complex fabrication equipment.
Data Source
AI summary
A wire rope for a running wire, has a core rope, a plurality of side strands arranged at an outer periphery of the core rope to be twisted together therewith, and a resin spacer interposed between the side strands, the core rope including a core rope main body composed of a plurality of wires and a resin coating layer outwardly surrounding the core rope main body so that the resin coating layer separates the core rope main body from the side strands, each of the side strands being composed of a plurality of further wires, and the resin spacer being provided with contour corresponding to an outer layer of the further wires of the side strands and extending between the wires of the outer layer of the side strands.