Patent Grant
11946201
The present invention relates to the technical field of steel wire rope processing production, and in particular, to a multilayer strand steel wire rope production device.
Devices for producing steel wire ropes mainly include a basket-type stranding machine, a large bearing-type tubular machine, and a tubular-type machine. The basket-type stranding machine mainly produces steel wire ropes having a thick specification, for example, 10 mm or more greater than the diameter of the steel wire rope; the tubular-type machine is mainly used for producing steel wire ropes having a finer specification, for example, 1.5 mm to 10 mm; a large bearing-type stranding machine is an updated version of the tubular-type machine, is changed into a large bearing-type from an early support wheel-type, and has a higher twisting speed. When multilayer strand steel wire ropes are subjected to laying-up on the tubular-type machine, outer winding strands are pre-deformed by means of pre-deformation, the pre-deformation treatment enables the steel wire ropes to have better tightness, so as to ensure that the steel wire ropes do not have loose ends.
In the prior art, strand wire payoff bases are fixed inside the drum during the production of the steel wire ropes, and do not rotate along with the drum; a plurality of outer winding strand steel wires respectively led out from a plurality of strand wire payoff bases is guided along the outer wall of the drum to a twisting point for twisting, and positions close to the twisting point are selected as mounting positions of the pre-former, not only mounting is easy, but the production of the steel wire ropes is also facilitated. Such a configuration mode can satisfy the production requirements for simple structures such as 7*7 and 7*3 of steel wire ropes during regular production, but is hardly applicable when producing the multilayer strand steel wire ropes having a complex strand wire structure, for example, a specification of 6*19-wsc alternating twisting structural steel wire ropes.
For the multilayer strand steel wire rope, a plurality of steel wires are twisted around the central steel wire into outer winding strands; the outer winding strands may be steel wire strands having the same specification, and may also be steel wire strands having multiple different specifications according to actual needs; and then a plurality of the outer winding strands are twisted around a center strand into the multilayer strand steel wire rope. The center strand may be a steel wire strand having the same specification as that of the outer winding strand, and may also be a steel wire strand having other specifications according to actual needs. The operating principle of existing tubular-type stranding devices is that: a plurality of steel wires drawn by a payoff spool are guided by a general wire guide mechanism, are required to be pre-deformed by means of a pre-former, and then are twisted at the hub; the position of the pre-former is very close to the hub (i.e., the twisting point). However, the applicant finds out that when the existing tubular-type stranding devices are used for producing the multilayer strand steel wire ropes, the problems of outward protrusion, core exposure, and blistering occur very easily, that is, the central steel wire of the outer winding strand protrudes outwardly and is exposed, so that the performance of the multilayer strand steel wire rope is severely influenced, causing the whole roll of the multilayer strand steel wire rope to be scrapped; if the pre-former is not used in the prior art, although twisting the outer winding strands on the center strand avoids outward protrusion and exposing of the central steel wire of the outer winding strand, but a serious loose end problem easily occurs. The outward protrusion phenomenon of the central steel wire occurs after an outer winding strand wire passes the pre-former, and the reasons are, on one hand, a subtle difference in models such as the diameters of strand wires, and on the other hand, that the pre-former would cause the outer winding strand to be bent in a wavy manner, so that gaps are generated between outer winding steel wires, thereby providing the probability of outward protrusion of the central steel wire of the outer winding strand. For example, when performing laying-up production in an initial operation, no abnormality is found in the obtained multilayer strand steel wire ropes; however, when continuing to operate by changing to next batch of strand wires when a payoff unit reaches a fixed length, there is a probability of occurrence of the outward protrusion phenomenon of the central steel wire of the outer winding strand, and if it is not found in time, waste products would be generated. For another example, when 7*19−φ3.0 mm and 7*19−φ3.2 mm of galvanized steel wire ropes having the same structure are produced, the diameter specifications of the two steel wire ropes are similar, but the twisting pitches of outer winding strands constituting the steel wire ropes are different. The two are subjected to laying-up in an existing tubular-type machine, no abnormality is found in producing 7*19−φ3.0 mm, and the abnormal phenomenon of outward protrusion of the outer winding strand occurs when changing to laying-up of 7*19−φ3.2 mm of strand wires after the production ends. At present, no one has done further research on this problem at home and abroad.
In view of the disadvantages of the prior art, the present invention provides a multilayer strand steel wire rope production device. A pre-former is fixedly provided on the outer surface of a drum, and outer winding strands are released from an outer winding strand payoff spool and then are pre-deformed in advance, so that the occurrence of problems of outward protrusion, core exposure, and blistering of central steel wires of the outer winding strands is significantly reduced, the quality of the multilayer strand steel wire rope is ensured, and waste is greatly reduced. Specifically, implementation is achieved by means of the following technologies.
A multilayer strand steel wire rope production device, including a drum, where a center strand payoff spool and a plurality of outer winding strand payoff spools are provided in the drum, pre-formers corresponding to the outer winding strand payoff spools and a first wire guide mechanism are provided on the outer surface of the drum, and the first wire guide mechanism is close to the corresponding outer winding strand payoff spool; one end of the outer surface of the drum away from the first wire guide mechanism is provided with a second wire guide mechanism, and a hub is additionally provided and located on one side of the drum close to the second wire guide mechanism; outer winding strands drawn from the plurality of outer winding strand payoff spools sequentially pass the first wire guide mechanism, the pre-former, and the second wire guide mechanism, and are guided to the hub for gathering to complete strand wire twisting.
The multilayer strand steel wire rope production device provided in the present patent focuses on how an outer winding strand is twisted on a center strand so as to avoid outward protrusion and exposure of a central steel wire of the outer winding strand, and as for how to produce the outer winding strand and the center strand, the structure of the multilayer strand steel wire rope production device is basically the same as the common tubular-type stranding device in the market at present. Therefore, the difference between the present patent and the prior art is that: a pre-former is independently provided at the tail end of a drum in the existing tubular-type stranding device, that is, being located between the tail end of the drum and a hub, rather than being provided on the drum. By using the technical solution of the present patent, the position of the pre-former is adjusted to be close to the outer winding strand payoff spool. In the case of knowing a twisting pitch and a twisting angle of the multilayer strand steel wire rope, and a twisting pitch of the outer winding strand, and knowing that the position of the outer winding strand payoff spool is fixed with respect to the drum (that is, a distance, which is parallel to the axis of the drum, between the center of the outer winding strand payoff spool and the second wire guide mechanism is known) and the position of the hub is fixed with respect to the drum (that is, a distance between a point of tangency between the outer winding strand and the outer winding strand payoff spool and the first wire guide mechanism is known), the position of the pre-former is adjusted, that is, a proper distance, which is parallel to the axis of the drum, between the pre-former and the second wire guide mechanism is selected, so as to effectively avoid the phenomena of outward protrusion and core exposure of the central steel wire of the outer winding strand. In such a technology that the pre-former is provided on the drum, and the outer winding strand released by each outer winding strand payoff spool is pre-deformed by means of the pre-former, at present, no one has provided similar technical solutions in the art. Compared with the prior art, the technology in the present patent can fundamentally solve the phenomena of exposure and outward protrusion of the central steel wire of the outer winding strand after the multilayer strand steel wire rope is subjected to laying-up by using a tubular-type machine, and can ensure that this problem would not occur repeatedly (for example, after strand wires in a payoff base are used up, laying-up is performed by changing to another batch of strand wires or changing to strand wires having another twisting pitch specification), that is, continuous normal production of the multilayer strand steel wire rope is achieved, thereby greatly facilitating the actual production process.
Preferably, a calculation method of the position of the pre-former is:
S1. the twisting angle of the multilayer strand steel wire rope is α, and when the drum rotates for a circle, the number of twisting circles of the outer winding strands on the drum is (1−cos α) circles.
S2. the outer winding strands are released from the outer winding strand payoff spools till to the hub for finishing the twisting, the total number of circles for the drum to rotate is N=(L1+L2+L3)/T1; the number of twisting circles of the outer winding strands is N′=N(1−cos α);
a theoretical exposure value of the central steel wire of the outer winding strand on a unit twisting pitch is
ΔL=T2−(L1+L2+L3)/[N′+(L1+L2+L3)/T2]
after a conversion,
ΔL=T2−T1T2/[(1−cos α)T2+T1] is obtained;
a distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism and the center of the second wire guide mechanism is L1, a distance between a point of tangency between the outer winding strand and the outer winding strand payoff spool and the first wire guide mechanism is L2, a distance between the center of the second wire guide mechanism and the hub is L3, the twisting pitch of the multilayer strand steel wire rope is T1, and the twisting pitch of the outer winding strand is T2.
S3. a theoretical threshold of exposure of the central steel wire of the outer winding strand from the payoff spool to the pre-former is L0, and when the exposure amount of the central steel wire of the outer winding strand reaches L0, a theoretical length of the required outer winding strand is L′=L0T2/ΔL.
S4. L is calculated according to a theoretical formula L=L1+L2−L′, L is a distance, which is parallel to the axis of the drum, between the pre-former and the center of the second wire guide mechanism, that is, the position of the pre-former.
A backward calculation method is specifically used for the position of the pre-former. A certain A point of the outer winding strand is used as a reference point, in the whole process of releasing A point from the outer winding strand payoff spool till to be finally twisted on the center strand, this section of outer winding strand is first preset, a theoretical threshold L0 of outward protrusion of the central steel wire of the outer winding strand is determined, and when the drum rotates and is twisted, the exposing amount of the central steel wire of the outer winding strand in one outer winding strand twisting pitch T2 is ΔL. When one section of outer winding strand is continuously twisted on the surface of the center strand, the accumulated total exposing amount of the central steel wire of the outer winding strand is increased gradually, when the accumulated amount exceeds the theoretical threshold L0, in the process of deforming by means of the pre-former, it is considered that the problem of outward protrusion occurs to the central steel wire of the outer winding strand. Therefore, when the outer winding strand is continuously twisted, the theoretical threshold L0 is divided by ΔL to obtain the number of twisting pitches at which outward protrusion is just not determined, and then is multiplied by the twisting pitch T2 of the outer winding strand, that is, to obtain the specific position of the pre-former when ensuring that outward protrusion of the central steel wire is just not determined for this section of outer winding strand. However, in the prior art, when the pre-former is conventionally provided at the hub, the length of the outer winding strand from the payoff base to the pre-former is basically equal to L1+L2+L3, the exposing amount (L1+L2+L3)ΔL/T2 of the central steel wire accumulated at the length would be far greater than the theoretical threshold set by us. Therefore, the phenomena of outward protrusion and exposure of the central steel wire would easily occur when passing the pre-former. The purpose of the calculation method is to calculate the position of the pre-former placed on the drum, parameters such as the theoretical threshold L0 in the practical production process are determined according to a large number of experiments and practical experience, and are related to the diameter of the multilayer strand steel wire rope. However, the calculation methods and formulas provide a new idea for how to solve the problems of overturning and exposing of the central steel wire of the outer winding strand of the multilayer strand steel wire rope. Because the multilayer strand steel wire rope comprises multiple outer winding strands, multiple outer winding strand payoff spools exist and are arranged inside the drum in line. According to the positions of the outer winding strand payoff spools and the position of the hub, the position of the pre-former corresponding to the outer winding strand payoff spools can be determined by using the calculation formulas. Therefore, it is ensured that the problems of outward protrusion and core exposure would not occur after the central steel wire of each outer winding strand is twisted.
Preferably, the theoretical threshold of exposure of the central steel wire of the outer winding strand is L0≤6.5 D, and D is the diameter of the multilayer strand steel wire rope. By means of calculation of the applicant, when the value of the theoretical threshold does not exceed 6.5 D, the produced multilayer strand steel wire rope can just satisfy the quality requirements. When the value of the theoretical threshold is greater than 6.5 D, the problems of overturning and exposure of the central steel wire of the outer winding strand would easily occur.
Preferably, a stable tensile force provided by the outer winding strand payoff spool for the steel wire is 2-10% of a strand wire breaking force.
More preferably, the stable tensile force provided by the outer winding strand payoff spool for the steel wire is 6% of the strand wire breaking force.
Preferably, the pre-former is one of a needle-type deformer, a bearing deformer, a triangle deformer, a hexagon deformer, and a special-shaped deformer.
Compared with the prior art, the beneficial effects of the present invention are as follows:
1. The technical means that is not used by a person skilled in the art is used in the present application. The pre-former is fixed on the drum, and the specific position of the pre-former is defined, so that quality problems such as outward protrusion and core exposure occurred in the central steel wire of the outer winding strand can be better prevented;
2. the product quality of the multilayer strand steel wire rope is effectively improved, the product scrap rate is reduced, and the costs are greatly saved.
In the drawings: 1. a drum; 2. an outer winding strand payoff spool; 3. a pre-former; 4. a first wire guide mechanism; 5. a second wire guide mechanism; 6. a hub; 7. an outer winding strand; 8. a center strand payoff spool.
The technical solutions of the present invention are clearly and fully described below. Apparently, the described embodiments are merely some of the embodiments of the present invention, but not all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by a person of ordinary skill without involving an inventive effort shall fall within the scope of protection of the present invention.
As shown in
In the following embodiment, the multilayer strand steel wire rope used therein is 6*19-wsc alternating twisting structure of steel wire rope having a steel wire rope diameter of 3.2 mm, the specific structure of the steel wire rope is (0.265+6*0.245+12*0.245)+6*(0.245+6*0.205+12*0.205), the twisting pitch of the steel wire rope is T1=21.5 mm, and the twisting pitch of the outer winding strand is T2=6.5 mm or 13.5 mm.
A distance, which is parallel to the axis of the drum, between the pre-former and the center of the second wire guide mechanism is L. A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism and the center of the second wire guide mechanism is L1. A distance between a point of tangency between the outer winding strand and the outer winding strand payoff spool and the first wire guide mechanism is L2. A distance between the center of the second wire guide mechanism and the hub is L3.
As shown in
For the position of the pre-former on the drum, that is, the calculation method of L is:
S1. the twisting angle of the multilayer strand steel wire rope is α=arctan π[(0.265+4*0.245)+(0.245+4*0.205)]/21.5=18.64°, and when the drum rotates for a circle, the number of twisting circles of the outer winding strands on the drum is (1−cos α) circles.
S2. the outer winding strands are released from the outer winding strand payoff spools till to the hub for finishing the twisting, the total number of circles for the drum to rotate is N=(L1+L2+L3)/T1; the number of twisting circles of the outer winding strands is N′=N(1−cos α);
a theoretical exposure value of a central steel wire of the outer winding strand on a unit twisting pitch is
ΔL=T2−(L1+L2+L3)/[N′+(L1+L2+L3)/T2];
after a conversion,
ΔL=T2−T1T2/[(1−cos α)T2+T1] is obtained;
a distance, which is parallel to the axis of the drum, between the pre-former and the center of the second wire guide mechanism is L; by means of measurement, a distance, which is parallel to the axis of the drum, between the center of number one outer winding strand payoff spool and the center of the second wire guide mechanism is L1=6500 mm; a distance between a point of tangency between the outer winding strand and the outer winding strand payoff spool and the first wire guide mechanism is L2=500 mm; a distance between the center of the second wire guide mechanism and the hub is L3=500 mm; a twisting pitch of the multilayer strand steel wire rope is T1=21.5 mm, and a twisting pitch of the outer winding strand is T2=13.5 mm, so as to obtain ΔL=0.43 mm by means of calculation.
S3. a theoretical threshold of exposure of the central steel wire of the outer winding strand is L0=6.5 D=20.8 mm, and a theoretical length of the required outer winding strand is L′=653 mm by means of calculation.
S4. L=6347 mm is calculated according to the formula L=L1+L2−L′, that is, L=97.64% L1.
Similarly to number one outer winding strand payoff spool, a distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number two outer winding strand payoff spool and the second wire guide mechanism is L1=5500 mm, ΔL=0.43 mm, and L=5347 mm of number two pre-former is calculated, that is, L=97.21% L1.
By analogy, a distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number three outer winding strand payoff spool and the second wire guide mechanism is L1=4500 mm, and L=4347 mm of number three pre-former is calculated, that is, L=96.6% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number four outer winding strand payoff spool and the second wire guide mechanism is L1=3500 mm, L=3347 mm of number four pre-former is calculated, that is, L=95.63% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number five outer winding strand payoff spool and the second wire guide mechanism is L1=2500 mm, L=2347 mm of number five pre-former is calculated, that is, L=93.88% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number six outer winding strand payoff spool and the second wire guide mechanism is L1=1500 mm, L=1347 mm of number six pre-former is calculated, that is, L=89.8% L1.
The center strand payoff spool is used for releasing a center strand, and therefore, no pre-former is provided.
A multilayer strand steel wire rope production device same as that selected in embodiment 1 is selected in this embodiment, and the difference is that a twisting pitch of an outer winding strand selected in this embodiment is T2=6.5 mm, and ΔL=0.1 mm is calculated. When a theoretical threshold of exposure of a central steel wire of the outer winding strand is L0=20.8 mm, L′=1352 mm is calculated.
Furthermore, a calculation method same as that in embodiment 1 is used, L1=6500 mm, L=5648 mm of No.1 pre-former is calculated, that is, L=86.89% L1.
Similarly to number one outer winding strand payoff spool, a distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number two outer winding strand payoff spool and the second wire guide mechanism is L1=5500 mm, and L=4648 mm of number two pre-former is calculated, that is, L=84.51% L1.
By analogy, a distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number three outer winding strand payoff spool and the second wire guide mechanism is L1=4500 mm, and L=3648 mm of number three pre-former is calculated, that is, L=81.06% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number four outer winding strand payoff spool and the second wire guide mechanism is L1=3500 mm, L=2648 mm of number four pre-former is calculated, that is, L=75.65% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number five outer winding strand payoff spool and the second wire guide mechanism is L1=2500 mm, L=1648 mm of number five pre-former is calculated, that is, L=65.92% L1.
A distance, which is parallel to the axis of the drum, between the center of the first wire guide mechanism corresponding to number six outer winding strand payoff spool and the second wire guide mechanism is L1=1500 mm, L=648 mm of number six pre-former is calculated, that is, L=43.2% L1.
The center strand payoff spool is used for releasing a center strand, and therefore, no pre-former is provided.
This comparative example is basically same as embodiment 1, and the difference is that a theoretical threshold of exposure of a central steel wire of the outer winding strand according to the comparative example is L0=6.0 D.
A calculation method same as that in embodiment 1 is used to obtain:
L=6420 mm of number one pre-former, that is, L=98.77% L1;
L=5420 mm of number two pre-former, that is, L=98.55% L1;
L=4420 mm of number three pre-former, that is, L=98.22% L1;
L=3420 mm of number four pre-former, that is, L=97.71% L1;
L=2420 mm of number five pre-former, that is, L=96.8% L1;
L=1420 mm of number six pre-former, that is, L=94.67% L1.
This comparative example is basically same as embodiment 1, and the difference is that a theoretical threshold of exposure of a central steel wire of the outer winding strand according to the comparative example is L0=7.0 D.
A calculation method same as that in embodiment 1 is used to obtain:
L=6297 mm of number one pre-former, that is, L=96.87% L1;
L=5297 mm of number two pre-former, that is, L=96.31% L1;
L=4297 mm of number three pre-former, that is, L=95.49% L1;
L=3297 mm of number four pre-former, that is, L=94.2% L1;
L=2297 mm of number five pre-former, that is, L=91.88% L1;
L=1297 mm of number six pre-former, that is, L=86.47% L1.
As shown in
Application example 1: detection of quality of multilayer strand steel wire ropes produced in multilayer strand steel wire rope production devices according to embodiments 1-3 and comparative examples 1 and 2.
According to YBT 4251, the surfaces of steel wires shall be smooth and flat, and defects such as interleaving, bending and broken wires shall not exist in the steel wires in a steel wire rope. Problems of overturinng and exposure of central steel wires of outer winding strands of the multilayer strand steel wire ropes produced in the multilayer strand steel wire rope production devices according to embodiments 1-3 and comparative examples 1 and 2 are detected. Specific results are shown in Table 1 below.
According to the detection results above, it can be known that the technical solution provided in the present patent is used, compared with the existing tubular-type stranding machine, outward protrusion and exposure of the central steel wires of the outer winding strands can be better prevented actually, and it is indicated that the calculation method about the position of the pre-former in the present application is relatively scientific and reasonable, and in line with the actual situation. Moreover, when a theoretical threshold of exposure of the central steel wire of the outer winding strand is L0=6.0 D and 6.5 D, the quality of the manufactured multilayer strand steel wire rope is high. However, the theoretical threshold is slightly increased to 7 D, a few quality problems would occur. This indicates that it is relatively accurate and reasonable that the value of the theoretical threshold L0 does not exceed 6.5 D.
| Number | Date | Country | Kind |
|---|---|---|---|
| 202010104096.1 | Feb 2020 | CN | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CN2020/077414 | 3/2/2020 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2021/164051 | 8/26/2021 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20230017733 A1 | Jan 2023 | US |
