Wire Rope Core Compaction for Strength and Flexibility
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Solution Overview
Problem
Existing wire rope manufacturing methods fail to produce wires with sufficient breaking strength and flexibility, as they often result in notches and uneven surface contact between core and strand wires, leading to reduced stability and flexibility.
Innovation Solution
The method involves pre-compacting the core rope before hammering and then stranding the wires, which causes the core rope surface to become smooth and circular, increasing the contact surface area and reducing pressure points, allowing for greater flexibility and breaking strength by compressing the wires into a smaller helix diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the core rope is compacted by rolling or hammering after stranding, then the fill level of the wire rope is increased, but notches form in the wires and the breaking strength is reduced
Solution Approach 1:
The core rope is compacted by rolling before the strands are stranded onto it. This preliminary compaction increases the fill level and creates a smooth circular surface on the core rope, which prevents notch formation when strands are later pressed against it during hammering. The harmful effect of notches is thus prevented in advance rather than occurring after stranding.
2Strength
If the core rope is hammered to smooth its surface, then the contact area between core rope and strands is increased, but the wires become loosely arranged reducing stability
Solution Approach 1:
The core rope is compacted by rolling before stranding to pre-smooth its surface and establish a stable circular cross-section. This preliminary smoothing action ensures that subsequent hammering after stranding will not create notches, while the wires remain securely held in their helical arrangement due to the pre-established stable core surface.
3Stability of the object's composition
If the wires are arranged in a tight helical configuration, then the wire rope has greater stability, but the flexibility and bending strength are reduced
Solution Approach 1:
The core rope is compacted by rolling to reduce its diameter and compress the helical wires into a tighter configuration. This parameter change in the core rope dimensions allows the outer strands to be arranged more loosely, improving flexibility and bending strength while the compacted core maintains stability through its smooth circular cross-section.
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
This approach significantly enhances the breaking strength and flexibility of the wire rope by reducing the risk of notch formation and allowing for a larger metal cross-section, resulting in a more stable and flexible product.
Implementation Method 1
hammering the core rope with hammers (12) simultaneously striking the core rope (3) to smooth its surface
Implementation Method 2
the diameter of the core rope is reduced by hammering, and strands are stranded onto the hammered core rope
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a method for producing a wire cable (1), wherein a core strand (3) is compacted and then braid strands (2) are stranded on the core strand (3), characterized in that the core strand (3) is hammered before stranding of the braid strands (2) in order to smooth the surface (10) thereof. According to the invention, a plastic layer is advantageously applied to the core strand (3) before stranding of the braid strands (2), wherein the braid strands (2) are pressed into the plastic layer (7), preferably while the plastic layer (7) is heated. In the preferred embodiment of the invention, the core strand is a core cable (3) and the braid strands are strands (2) of the wire cable (1) or the core strand is a heart strand and the braid strands are outer core strands of a core cable of the wire cable. The invention further relates to the wire cable (1) and a device for producing the wire cable (1).