Industrial Sling Helical Core Yarns
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Solution Overview
Problem
Non-metal industrial slings manufactured with untwisted core yarns suffer from uneven loop lengths, leading to premature failure as the shortest loops bear the entire load, resulting in catastrophic failure due to overloading, necessitating constant inspection and replacement.
Innovation Solution
Twisting the core yarns in a helical pattern during the manufacturing process, utilizing a machine that feeds the yarns through a cover with opposing twist fibers to create a helically-laid bundle, increasing the strength of the load-bearing core by 12-15% without additional machinery or complex methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If core yarns are wound in parallel without twisting, then the manufacturing process is simple, but the load-bearing capacity is insufficient due to uneven loop lengths
Solution Approach 1:
The patent applies parameter changes by twisting the core yarns in a helical pattern during the winding process, transforming the core structure from parallel to helical. This parameter change in the yarn arrangement increases load-bearing capacity by ensuring more uniform load distribution across all yarn loops, eliminating the weakness of uneven loop lengths while maintaining manufacturing simplicity through process integration.
2Strength
If more core yarns are used to compensate for uneven loop lengths, then the load-bearing capacity increases, but the sling weight increases
Solution Approach 1:
The helical twisting of core yarns changes the structural parameter of the core, enabling more efficient load distribution. This allows achieving the required load-bearing capacity with fewer yarns compared to parallel winding, thereby reducing sling weight while maintaining or improving strength performance.
3Reliability
If the shortest loops bear the entire load, then the manufacturing process is simple, but the reliability decreases due to premature failure
Solution Approach 1:
By changing the winding parameter from parallel to helical, the patent ensures that all core yarn loops engage uniformly under load. This eliminates the premature failure mechanism where shortest loops bear disproportionate loads, significantly improving reliability and service life while the integrated manufacturing process maintains ease of production.
Data Source
Figure 1~2
Figure 3a~3e
Figure 4~5
AI summary
A sling for industrial lifting made of a load-bearing core (1) and a cover (2). The cover (2) protects the plurality of yarns (3) that make-up the core (1). Each core yarn (3) is made of a number of core threads (4) twisted together. The core yarns (3) are twisted together where the twist is in the. same direction as the individual core strands and a different direction than the twist of the cover (2). The present invention describes the method of twisting the core yarns (3) together by inserting core yarns (3) substantially parallel into a cover (2) that has a twist opposite of each core strand. As the core strands are inserted into the cover (2), the twists of the individual core yarns (3) interact with the twist of the cover (2), resulting in the core yarns (3) twisting together.