Spliced Wire Rope Intermediate Piece for Smooth Running
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Solution Overview
Problem
Existing intermediate pieces for spliced wire ropes do not adequately extend service life and contribute to operational noise and vibrations, particularly in high-load applications like cable cars.
Innovation Solution
The introduction of preformed intermediate pieces with grooves and recesses that allow for a maximum 8% increase in rope diameter, facilitating smoother operation and reduced noise by evenly distributing strain, and are designed for easy integration during splicing with a deformable plastic core and reinforced splicing tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional intermediate pieces are used for splicing wire ropes, then the splicing process is simple, but the rope diameter varies significantly causing poor smooth running and increased noise
Solution Approach 1:
The intermediate piece features a variable wall thickness design where the wall thickness changes along the longitudinal axis. The thickest section is positioned at the splice point to compensate for diameter variations, while the walls taper toward the ends. This localized variation in geometry ensures uniform rope diameter and smooth running without excessive noise.
2Ease of operation
If intermediate pieces with complex geometry are used to reduce diameter variation, then smooth running improves, but manufacturing complexity increases
Solution Approach 1:
The intermediate piece is pre-formed with the optimized variable wall thickness profile before insertion into the rope. This preliminary shaping allows the complex geometry to be manufactured once using standard extrusion or molding processes, rather than requiring complex assembly during splicing. The pre-formed geometry then ensures uniform rope diameter and reduced noise during operation.
3Manufacturing precision
If the intermediate piece wall thickness is increased to reduce diameter variation, then rope uniformity improves, but the intermediate piece becomes harder to insert during splicing
Solution Approach 1:
The intermediate piece features a dynamic wall thickness profile that adapts to the splicing requirements. The walls are thickest at the splice point where structural support is needed, and gradually taper toward the ends where flexibility and ease of insertion are prioritized. This dynamic geometry allows the piece to be easily inserted while maintaining rope uniformity once in position.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the service life of wire ropes by ensuring even diameter changes and reduces operational noise and vibrations, improving the smooth running of the rope without additional manufacturing effort.
Implementation Method 1
the distances a between the inserts 12 and the plastic core 11 are each dimensioned such that they correspond at least approximately to the expansion that results from the radial outward flow of the plastic core 11 after a certain initial operating time of the wire rope
Implementation Method 2
The plastic core 11 is rod-shaped and is heated during manufacturing in such a way that the strands 15 with their corrugated surface structure result in a form-fitting connection by deformation of the circumferential area 11' of the plastic core 11
Data Source
Figure 1~2
Figure 3~5
AI summary
An intermediate piece for a spliced wire rope is elongated and pre-formed such that it has a longitudinally extending recess (21) and additionally grooves (22, 23, 24) distributed around its circumference, into which strands (15, 15') of the wire rope (10') can be inserted. The intermediate piece (20) is correspondingly thicker towards the middle than at the ends with the thin walls (20'), with a continuous change in thickness from the outside to the inside. With this intermediate piece according to the invention for use in splicing a wire rope, a uniformly increasing and decreasing rope diameter of a maximum of 8% of the nominal diameter is achieved, which has a positive effect on the smooth running of the rope, and these intermediate pieces can also be easily inserted during splicing.