New high performance cableway wire rope

Abstract: with the development of passenger ropeway towards high speed, large span, high drop, super long line and long service life, higher requirements are put forward for the performance of steel wire rope for passenger ropeway. In order to better meet the requirements of passenger ropeway wire rope in terms of good stability, small elongation and good diameter maintenance, a new high-performance ropeway wire rope is developed. The rope core material adopts high molecular polymer. Through improving the production process and strict quality control, 6 × 36WS、6 × 26WS、6 × 25Fi、6 × 19S and other structural models of cableway steel wire rope. The test shows that the product quality and mechanical properties of the new high-performance cableway wire rope meet the design requirements.

Key words: new rope core; High molecular polymer; High performance

0 Introduction

Cableway wire rope has been widely used in tourism, urban transportation and other fields. With the development of tourism industry, the height difference between upper and lower stations of cableway is becoming larger and larger, and the line is becoming longer and longer. Especially for detachable cableway, higher requirements are put forward for the uniformity and stability of wire rope diameter. At the same time, due to the limited tensioning stroke and short distance of the line, the requirements for elongation are also more strict.

1 production process of cableway wire rope

1.1 steel wire rope core

At present, the core of steel wire rope is more difficult to manufacture than that of steel wire rope in developed countries. However, the core of steel wire rope is more difficult to maintain the diameter of steel wire rope. Compared with that of steel wire rope in developed countries, this kind of steel wire rope can maintain the core of steel wire rope.

The new rope core technology is developed, and the polymer is used as the main material of the new rope core. The cross section comparison of fiber core steel wire rope and polymer core steel wire rope is shown in Figure 1. After many performance tests such as toughness and strength, its indexes are higher than the current fiber rope core materials, reaching the international level of similar products.

New high performance cableway wire rope

(a) Fiber core steel wire rope (b) polymer core steel wire rope

1.2 production process

Based on the research and development of polymer rope core, the production process and quality control are also continuously improved. Optimize the wire rope process through computer drawing technology, obtain more accurate geometric parameters of wire rope, make the steel wire ratio in the strand more reasonable, calculate the filling area of polymer rope core, determine the appropriate diameter of rope core, and realize the full filling degree of rope core. Steel wire drawing adopts post plating technology to ensure that the steel wire has high mechanical properties and zinc layer thickness. The rope strand adopts the production method of tight twisting to improve the twisting quality of the rope strand. The steel wire has no electric connection, so as to avoid the impact of defects caused by the electric connection quality on the service life of the steel wire rope.

With 6 × Taking 36ws + spc-40mm steel wire rope as an example, the twist distance multiple of steel wire rope is 7, the twist coefficient is 3.0675, the diameter of rope strand is 40 / 3.0675 = 13mm, and the twist multiple of strand is 8.5. It is determined that the diameter proportion coefficient of outer steel wire is 5.688, so the diameter of outer steel wire is 2.28mm. The wire diameter of each layer is calculated according to the diameter proportion of each layer of rope strand is 1:0.6175:0.7975:0.8129:1.0721, which are 1.41, 1.81, 1.85 and 2.44mm respectively, After arranging the steel wires of each layer of rope strand according to the elliptical shape of twist shrinkage and structural law by CAD drawing, confirm the gap value between wires. At the same time, combined with the actual production experience, appropriately increase the diameter of central steel wire, and determine that the wire diameter of rope strand is (from inside to outside) 2.60 + 1.85 + 1.8/1.40 + 2.28mm and the diameter of rope strand is 12.92mm.

The actual diameter of the steel wire rope is controlled by 1.03 times the nominal diameter, i.e. 41.2mm. The calculated filling area of the rope core is 303.3mm, which is converted into the rope core diameter of 19.6mm. According to 6 × 36ws structural experience finally determined that the rope core diameter was 20mm. A suitable pre deformer is used for the production of finished products, and the pre deformation parameters and post deformation parameters are adjusted accordingly for the polymer rope core.

The above technology is applied to produce a new type of high-performance cableway steel wire rope, model 6 × 36ws + spc-40mm-1870mpa and 6 × 36ws + spc-48mm-1960mpa, the measured diameter and metal cross-sectional area of steel wire rope are shown in Table 1. The gap between the strands of the steel wire rope can be seen to be evenly filled with the extrudate of the rope core (see Figure 2). The physical photo of the rope core after the strand is completely removed is shown in Figure 3. The rope core presents a perfect spiral shape, the thickness of the filled part of the strand gap is uniform, and the product quality and measured data meet the design requirements.

2. Performance index of steel wire rope

The performance test of strand breaking steel wire and the breaking tension test of the whole rope shall be carried out on the steel wire rope. See Table 2 for the test data of strand breaking steel wire. The strength of steel wire is uniform, and the indexes such as bending, torsion and weight of galvanized coating are higher than the standard requirements of GB / t26722-2011 steel wire rope for cableway, meeting the requirements of tensile strength, toughness and anti-corrosion performance. six × The measured breaking force of 36ws + spc-40mm steel wire rope is 1056kn, which is 36kn higher than the standard specified in GB / t26722-2011 steel wire rope for cableway and 20KN higher than the reference value in the product manual of a foreign enterprise; six × The measured breaking force of 36ws + spc-48mm steel wire rope is 1585kn, which is 45KN higher than that specified in GB / t26722-2011 steel wire rope for cableway and 13kn higher than the reference value in the steel wire rope product manual of a foreign enterprise, meeting the bearing requirements.

3 practical application of cableway wire rope

The varieties of new high-performance cableway steel wire rope include six strand and eight strand wire contact round strand steel wire rope. The nominal diameter range is 20 ~ 70mm, the nominal tensile strength is 1670 ~ 2060mpa, and the maximum production capacity can reach 100t per steel wire rope. It has been applied to Cableways in many scenic spots. In practical application, the diameter change rate is in the range of 1.8% ~ 3.8%, and the one-year elongation is less than 1.5 ‰, which delays the secondary interpolation time and reduces the economic loss caused by the shutdown of interpolation. See Table 3 for specific use data. The new high-performance cableway steel wire rope has stable structure, uniform stress of each strand, more accurate diameter control, better diameter retention during operation, and better meets the requirements of detachable cableway for steel wire rope; The gap between steel wire strands is filled with rope core, which reduces the friction and impact between steel wire strands. At the same time, the gap filling effectively hinders the erosion of rain and dust, and improves the service life of steel wire rope; The elongation of steel wire rope is smaller, which is conducive to the application of cableway with high drop, large elevation angle or ultra long line.

4 Conclusion

After relevant technology research and development, the new high-performance cableway wire rope has reached the performance level of similar international products, and has been applied to the operation of several passenger cableways. Relevant technical achievements have been transformed into two national invention patents, which is beneficial to the overall improvement of domestic cableway equipment level and technological progress.