How to extend the service life of the wire rope
1. Correctly install and start the new wire rope.
The first rule of thumb when installing a new wire rope is that any kinks in the wire rope should be avoided. This can be avoided by properly unloading the wire rope from the I-beam or coil and installing it on your equipment. The steel wire rope is installed on the smooth reel, and the layer of steel wire rope must be tightly wound, and then the remaining wire rope is wound on the reel with a tension of 1%~2% of the small breaking force of the wire rope. For spiral wire rope reels with rope grooves, it should be noted that the nominal diameter of the wire rope matches the spacing between grooves, the radius of the rope groove, and the depth of the side grooves. For off-bar type rope groove drums, in addition to paying attention to the coordination of the wire rope diameter with the rope groove of the drum and the inner width of the drum, it is also necessary to pay attention to the system inclination angle to match the wire rope load and running speed.
After the wire rope is installed, it should be run for a period of time without any load, and then run for a period of time with a smaller load and a lower speed, so that the strands and wires in the wire rope can be adjusted tightly and eliminate excess stress.
2. Assess the hazard to the system from structural elongation of the wire rope.
When the wire rope is first put into use, the strands and strands and the strands and the rope core are usually stretched in the process of being in place, which is called "structural stretch". Because this is the inherent structural characteristics of the helical bridging of the wire rope strands and the helical bridging of the strands and wires, the length of the wire rope will be extended when the external force is stretched. The structure of the wire rope is different, and the elongation is also different, usually %~1% of the rope length. If structural elongation needs to be minimized, in addition to the selection of wire ropes of specific construction, the wire ropes can be pre-tensioned before leaving the factory. In addition, wire ropes are elastically elongated due to the recoverable deformation of the metal itself.
3. Cut off the end of the wire rope in time to eliminate the wear point.
If in the daily inspection of the wire rope, it is found that the wear of the tail wire rope is expanding or a large number of fatigue broken wires occur, it is better to cut off this section of the wire rope. Removing these worn parts can turn the whole wire rope into a "new wire rope" and put it back into use, thereby greatly extending the service life of the wire rope. This may require the initial length of wire rope to be slightly longer than what you would normally use. The wire at the end of the crane wire rope will break due to wear and vibration fatigue, so cutting a small section of the wire rope there and re-wedging the wire rope into the system will help prolong the service life of the wire rope. Once the wire is found to be broken, the wire rope from that point to the clamp should be cut off, and the entire portion of the wire rope covered by the broken wire should be cut off. At the tooth socket, at least m~m should be removed; at the chuck and fixture, it should be cut to the part where there is no broken wire.
At the balance guides equipped with most overhead cranes, the parts where the wire ropes are in contact with the balance guides are prone to fatigue. If you cut off a small part of the wire rope at one end of the drum, so that the contact part of the wire rope and the guide is staggered, it is also like a new wire rope, which increases the service life of the wire rope. However, the cutting work must be carried out before the wear of the wire rope at the balance guide is serious, and it must be cut on the same drum to which the wire rope is connected.
4. Timely maintenance or replacement of reels and slides.
When it is found that there are worn grooves at the bottom of the drum rope groove or chute, and the surface in contact with the wire rope is not smooth, please repair it with steel repair agent and repair or replace it by machining.
The diameter of the rope groove or the chute of the drum is worn to a degree that exceeds the nominal diameter of the wire rope, and it has lost its supporting effect on the wire rope. Please replace it.
5. Regularly clean and lubricate the wire rope to reduce wear.
Regular manufacturers have scientifically lubricated the wire rope before it leaves the factory, so that the wire rope strand and the steel wire in the strand can be automatically adjusted with the movement and bending of the wire rope. However, it is not possible to guarantee adequate lubrication of the wire rope throughout its service life. Therefore, regular lubrication over the life of the wire rope is critical.
During work, the surface of the wire rope will be covered with sand, stone chips or other substances or even chemical dust, which will prevent the lubricating oil added on site from infiltrating the wire rope or directly wear and corrode the wire rope. Therefore, it is necessary to clean the wire rope before lubrication. The lubricating oil used should be of low consistency to allow penetration. There are usually 3 lubrication methods: drip, spray, and hand brush. Either way, lubrication should be applied at the bends of the wire rope, such as grooves. We recommend that you use lube on top of the bend in the running rope as this is where the rope strands are stretched by the bend and are more permeable. In addition to this, tool pressure lubrication can also be used.
The service life of the wire rope is directly related to the effectiveness of the lubrication method and quantity you apply. Proper lubrication must make a moderate high-quality oil film adhere to each steel wire, reduce friction and prevent corrosion, and the oil layer must be flexible, not cracked when cold, and not dripping when heated. Do not use too much grease on the wire rope, because this will cause the wire rope to adhere to and rub against hard objects, thereby damaging the wire rope. Also avoid using used machine lubricating oil. Hard objects often contain salts and acidic substances that damage the wire rope. The dropping point of lubricating oil and grease in domestic circulation is closely related to temperature.
6. The head and tail of the wire rope are upside down (the end is upside down).
The severely worn parts of many wire rope running systems are usually too far from the end of the wire rope or the worn part is too long to be removed. In this case, you can turn the wire rope upside down, so that the less worn parts are replaced with the more wear-prone areas. This operation is beneficial for sloping ropes and traction ropes, but must be reversed before the ropes are worn down to the level of degrading and scrapping. During operation, the wire rope should be relieved of stress, not pulled strongly, and try to avoid twisting and kinking of the wire rope.
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