How to prolong the service life of steel wire rope

1. install and start the new steel wire rope correctly.

The first principle for installing a new wire rope is to avoid any kink in the wire rope. This condition can be avoided by properly unloading the steel wire rope from the I-beam or reel and installing it on your equipment. When the steel wire rope is installed on the smooth drum, the layer of steel wire rope must be tightly wound, and then the remaining steel wire rope shall be wound on the drum with the tension of 1%~2% of the small breaking force of the steel wire rope. For spiral steel wire rope drum with rope groove, pay attention to the matching of the nominal diameter of steel wire rope with the spacing between grooves, the radius of rope groove and the depth of side tooth groove. For the off bar rope groove drum, in addition to the coordination of the diameter of the steel wire rope with the rope groove and the inner width of the drum, it should also be noted that the inclination angle of the system should match the load and running speed of the steel wire rope.

After the steel wire rope is installed, it shall run for a period of time without any load, and then run for a period of time with a small load and a low speed, so that the rope strands and steel wires in the steel wire rope can adjust closely and eliminate excess stress.

2. evaluate the damage of structural elongation of steel wire rope to the system.

When the steel wire rope was put into use at the beginning, it usually elongated during the positioning between strands and between strands and rope core, which is called "structural elongation". This is because the inherent structural characteristics such as the spiral closure of steel wire strands and the spiral closure of steel wire strands will extend the length of the steel wire rope when the external force is stretched. The elongation of steel wire rope varies with its structure, usually%~1% of the rope length. If it is necessary to reduce the structural elongation, in addition to selecting the steel wire rope with specific structure, the steel wire rope can be pre tensioned before leaving the factory. In addition, the steel wire rope has elastic elongation, which is caused by the recoverable deformation of the metal itself.

3. timely cut off the end of the steel wire rope to eliminate the wear points.

If it is found during the daily inspection of the steel wire rope that the wear of the tail steel wire rope is expanding or a large number of fatigue broken wires occur, this section of steel wire rope shall be cut off. Cutting off these worn parts can change the whole steel wire rope into a "new steel wire rope" and put it back into use, thus greatly extending the service life of the steel wire rope. This may require the initial length of the wire rope to be slightly longer than the length you normally use. The steel wire at the end of the crane steel wire rope will break due to wear and vibration fatigue. Therefore, cutting a small section of the steel wire rope and re wedging the steel wire rope into the system will help to prolong the service life of the steel wire rope. Once the steel wire is found to be broken, the steel wire rope from this place to the fixture shall be cut off, and the whole part of the steel wire rope covered by the broken wire shall be cut off. At least m ~ m should be removed from the alveolar; At the collet and fixture, it shall be cut to the position where there is no broken wire.

At the balance guide provided by most overhead cranes, the part where the steel wire rope contacts with the balance guide is prone to fatigue. If you cut off a small section of the steel wire rope at one end of the drum, so that the contact part between the steel wire rope and the guide is staggered, it is also like replacing a new steel wire rope, which increases the service life of the steel wire rope. However, it must be cut off before the steel wire rope at the balance guide is seriously worn, and it must be cut off on the same drum connected to the steel wire rope.

4. timely maintain or replace the drum and slide.

When the drum rope groove or chute bottom is found to be worn and the surface in contact with the steel wire rope is not smooth, please timely repair it with steel repair agent and repair or replace it by machining.

The rope groove or chute diameter of the drum is worn to times of the nominal diameter of the steel wire rope, which has lost its supporting effect on the steel wire rope. Please replace it.

5. clean and lubricate the steel wire rope regularly to reduce wear.

Regular manufacturers have carried out scientific lubrication treatment on the steel wire rope before leaving the factory, so that the steel wire strands and wires in the strands can be automatically adjusted with the movement and bending of the steel wire rope. However, it is impossible to ensure adequate lubrication of the wire rope throughout its service life. Therefore, regular lubrication during the service life of steel wire rope is very important.

During operation, the surface of the steel wire rope will be covered with sand dust, stone chips or other substances or even chemical dust, which will prevent the lubricating oil injected on site from penetrating into the steel wire rope or directly wearing and corroding the steel wire rope. Therefore, it is necessary to clean the steel wire rope before lubrication. The lubricating oil used shall be of low consistency to facilitate penetration. There are usually three lubrication methods: drip, spray and hand brush. Either way, lubrication shall be carried out at the bend (such as groove) of the steel wire rope. We recommend that you use lubricating oil at the top of the bending part of the running steel wire rope, because the steel wire rope strands are stretched due to bending, which is easier to penetrate. In addition, tools can be used for pressurized lubrication.

The service life of the wire rope is directly related to the effectiveness of the lubrication method and amount you use. Proper lubrication must make appropriate high-quality oil film adhere to each steel wire, reduce friction and prevent corrosion, and the oil layer must be flexible without cracking in cold and dripping in heat. Do not use too much grease on the steel wire rope, because it will cause the steel wire rope to adhere to hard objects and rub and squeeze with hard objects, thus damaging the steel wire rope. It is also forbidden to use used machine lubricating oil. Hard objects often contain salts and acids that damage the steel wire rope. The dropping point of lubricating oil and grease circulating in China is closely related to the temperature.

6. the head and tail of the steel wire rope are inverted (the tail end is inverted).

Many severely worn parts of the wire rope operating system are usually too far away from the end of the wire rope or the worn parts are too long to be removed. In this case, you can reverse the head and tail of the steel wire rope, so as to replace the parts with less wear to the areas easy to cause wear. This operation is very beneficial to the inclined rope and traction rope, but the tail end must be inverted before the wear degree of the steel rope reaches the degradation and scrapping standard. During operation, the steel wire rope shall be stress relieved and not pulled, and the steel wire rope shall be prevented from twisting and kinking as far as possible.