GALVANIZED WIRE ROPE
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Construction of rope is used to distinguish one rope from another based on the number of strands, number if position of the wires in a strand, and the core type of the rope (fibre core and steel core) to distinguish. As shown in Fig.1, the rope is made up of strands and each strands is made wires, with fibre core. Normally, a rope consists of six strands around a core in prescribed pitch.
Rope makes with 3 strands or more. Some spe- cial cases, besides, a rope is consists of six strands normally to achieve the balanced construction. In the case for elevators where special flexibility is required, eight strands are used.When non-torque is required, two or more layers of strands are used.
Laying of the strands
Laying is the method that the wires are positioned
to form lay, Cross lay strand is made by the same
diameter but different lay angle in multi-operation.
The parallel lay strand is made only in one opera-
tion so that the wires of each lay will be on the
same pitch.
Two position methods of wire
a. Cross Lay
This also known as point contact lay where the lay
angle of wires will be nearly equivalent for each
layer of wire of the same diameter. Tension stress
that works on the wire, thus, will become uniform.
However, fatigue resistance of rope will be less,
as bending stress will be added to each contact
point.
Three main types of cross lay strand as follow,
strand lay methods are list,
a. 1 X 7 b. 1 X 19 c. 1 X 24
b. Parallel Lay
Also known as equal lay, one operation lay or lin-
ear lay where the wires are positioned in such a
way that no space is left between wires, thus the
upper layer wires will fit perfectly into the groove of
the lower wires of the strand. Furthermore, wires
of different diameters are positioned
simultaneously, so that each layer will have the
same pitch and will be in contact with each other.
Few common strand lay methods are list as follow,
a. 6 X Fi (25) b. 6 X WS (36) c. 6 X S (19)
a. Seale Type
The number of wires of each layer is shown as
1+n+n and the numbers of wires of inner and
outer layers is same. The wire of outer layer fit
completely into the grooves of the inner layer
wires.
Seale type rope is thicker when compared to
other parallel lays and so it is superior, particu-
lar in its wear resistance and is mainly used for
elevators.
b. Warrington Type
The number of wire of the outer wire is double
that of the inner layer and through a combina-
tion of the inner and outer layers the spaces
between the wires is kept small. This
Warrington type rope is not being used to any
great degree recently.
c. Filler rope
The inner wires and the same number of thin
filler wires are used to till the spaces in the in-
ner and outer layers. This filler type rope is good
balance between the flexibility, fatigue resis-
tant and has the widest range of use among
parallel lay ropes.
d. Combination types
Apart from above three basic types, there are
another types called combination type. This is
the type, which mixed with Seale Type (outer
layer) and Warrington Seale type & Filler rope
(Inner layer).
Rope Core
A. Fiber Core (abbreviated FC)
FC
Fiber core has two functions,
(1) Support the strand and hold the shape of
strand at same time,
(2) Hold the rope grease and supply neces-
sary amount of grease inside the rope for
lubrication and prevent corrosion. In the
past, natural fiber was mainly used but
synthetic fiber will hold the grease well.
The characteristics of fibre core,
(a) The rope has a high flexibility.
(b) Impacts and vibrations to the rope are
absorbed.
(c) Holds rope grease well (in particular, in
the case of natural fiber),
(d) The unit and mass of the rope is small.
Moreover, synthetic fiber compared to
natural fiber is superior in its corrosion re-
sistance nature.
B. Steel Core
There are three strand types of steel core,
(1) Independent Wire Strand Core (IWSC)
IWSC has the strand as the core and those
that have the same construction as the side
strand are referred to as the common core.
(2) Independent Wire Rope Core (IWRC)
It has a single independent rope as the core.
Usually, 7 X 7 construction is use. Sometimes,
6 X 7 or 6 X 19 may be used.
(3) Center Fit Rope Core (CFRC)
This is the rope type, which the outer layer
strand of the core rope is fitted into the groove
of the inside
Laying of rope
In lay of rope, there are the ordinary lay and the
Lang°s lay.
(a) Ordinary lay (or regular lay) /
The lay of the rope and the lay of the strands
are in opposite directions, such as ordinary Z
lay and ordinary S lay.
(b) Lang°s lay /
The lay of the rope and the lay of the strands
are in the same direction, such as Lang°s Z lay
and Lang°s S lay.
,
(c) Comparison of the characteristics by laying of
rope
Preforming
Preforming is a method for lessening the springi-
ness of the rope by given each strand and wire a
form in advance. Ropes made through this method
are called preformed, or Tru-lay ropes. The strands
and wires do not fall apart even when the rope is
cut.
The rope being manufactured, at present, is prac-
tically all preformed ropes. The non-preformed
ropes are only for special use.
Breaking Load
As the breaking load, there is the concept of speci-
fied breaking load and the actual breaking load.
The specified breaking load is the standard value,
or the minimum value of the breaking load, while
the actual breaking load is the actual load during
testing.
The breaking load is determined by the nominal
tension of the wires making up the rope and is clas-
sified as shown in Table 2.
Kinds of Coating
Ropes are usually of the bright type but when cor-
rosion resistant nature is required the ropes are
coated. Among the kinds of coating, there is the
zinc coating and aluminum coating. Generally, gal-
vanizing is commonly used.
Greasing
Rope grease is applied to the rope at the same
time of manufacturing to prevent corrosion and also
to provide lubrication. Great care is taken to apply
the rope grease uniformly and so that it will pen-
etrate to the core and strand, through an impreg-
nation method.
Rope makes with 3 strands or more. Some spe- cial cases, besides, a rope is consists of six strands normally to achieve the balanced construction. In the case for elevators where special flexibility is required, eight strands are used.When non-torque is required, two or more layers of strands are used.
Laying of the strands
Laying is the method that the wires are positioned
to form lay, Cross lay strand is made by the same
diameter but different lay angle in multi-operation.
The parallel lay strand is made only in one opera-
tion so that the wires of each lay will be on the
same pitch.
Two position methods of wire
a. Cross Lay
This also known as point contact lay where the lay
angle of wires will be nearly equivalent for each
layer of wire of the same diameter. Tension stress
that works on the wire, thus, will become uniform.
However, fatigue resistance of rope will be less,
as bending stress will be added to each contact
point.
Three main types of cross lay strand as follow,
strand lay methods are list,
a. 1 X 7 b. 1 X 19 c. 1 X 24
b. Parallel Lay
Also known as equal lay, one operation lay or lin-
ear lay where the wires are positioned in such a
way that no space is left between wires, thus the
upper layer wires will fit perfectly into the groove of
the lower wires of the strand. Furthermore, wires
of different diameters are positioned
simultaneously, so that each layer will have the
same pitch and will be in contact with each other.
Few common strand lay methods are list as follow,
a. 6 X Fi (25) b. 6 X WS (36) c. 6 X S (19)
a. Seale Type
The number of wires of each layer is shown as
1+n+n and the numbers of wires of inner and
outer layers is same. The wire of outer layer fit
completely into the grooves of the inner layer
wires.
Seale type rope is thicker when compared to
other parallel lays and so it is superior, particu-
lar in its wear resistance and is mainly used for
elevators.
b. Warrington Type
The number of wire of the outer wire is double
that of the inner layer and through a combina-
tion of the inner and outer layers the spaces
between the wires is kept small. This
Warrington type rope is not being used to any
great degree recently.
c. Filler rope
The inner wires and the same number of thin
filler wires are used to till the spaces in the in-
ner and outer layers. This filler type rope is good
balance between the flexibility, fatigue resis-
tant and has the widest range of use among
parallel lay ropes.
d. Combination types
Apart from above three basic types, there are
another types called combination type. This is
the type, which mixed with Seale Type (outer
layer) and Warrington Seale type & Filler rope
(Inner layer).
Rope Core
A. Fiber Core (abbreviated FC)
FC
Fiber core has two functions,
(1) Support the strand and hold the shape of
strand at same time,
(2) Hold the rope grease and supply neces-
sary amount of grease inside the rope for
lubrication and prevent corrosion. In the
past, natural fiber was mainly used but
synthetic fiber will hold the grease well.
The characteristics of fibre core,
(a) The rope has a high flexibility.
(b) Impacts and vibrations to the rope are
absorbed.
(c) Holds rope grease well (in particular, in
the case of natural fiber),
(d) The unit and mass of the rope is small.
Moreover, synthetic fiber compared to
natural fiber is superior in its corrosion re-
sistance nature.
B. Steel Core
There are three strand types of steel core,
(1) Independent Wire Strand Core (IWSC)
IWSC has the strand as the core and those
that have the same construction as the side
strand are referred to as the common core.
(2) Independent Wire Rope Core (IWRC)
It has a single independent rope as the core.
Usually, 7 X 7 construction is use. Sometimes,
6 X 7 or 6 X 19 may be used.
(3) Center Fit Rope Core (CFRC)
This is the rope type, which the outer layer
strand of the core rope is fitted into the groove
of the inside
Laying of rope
In lay of rope, there are the ordinary lay and the
Lang°s lay.
(a) Ordinary lay (or regular lay) /
The lay of the rope and the lay of the strands
are in opposite directions, such as ordinary Z
lay and ordinary S lay.
(b) Lang°s lay /
The lay of the rope and the lay of the strands
are in the same direction, such as Lang°s Z lay
and Lang°s S lay.
,
(c) Comparison of the characteristics by laying of
rope
|
|
Ordinary lay 交互拈 |
Lang’s lay 同向拈 |
|
Appearance 外观 |
The wires are approximately parallel to the axis of the rope 钢丝的走向与钢丝绳的轴线近似平行 |
The wires form a certain angle with the rope axis 钢丝的走向与钢丝绳的轴线呈一定角度 |
|
Merits 优点 |
Kinks do not form easily and is easy to handle,the lays are tight and the form does not crumble. 不易打结，即使打结易解开，结构紧密，不易松散。 |
The wires are long and superior in wear resistance flexible and has good fatigue resistance nature. 耐磨性能和抗疲劳性能较好。 |
|
Demerits 缺点 |
Inferior in wear resistance nature and fatigue resistance nature compared to theLang’s lay.耐磨性能和抗疲劳性能较差。 |
The rope has a large torque and forms kinks easily反拨力大，容易打结。 |
Preforming is a method for lessening the springi-
ness of the rope by given each strand and wire a
form in advance. Ropes made through this method
are called preformed, or Tru-lay ropes. The strands
and wires do not fall apart even when the rope is
cut.
The rope being manufactured, at present, is prac-
tically all preformed ropes. The non-preformed
ropes are only for special use.
Breaking Load
As the breaking load, there is the concept of speci-
fied breaking load and the actual breaking load.
The specified breaking load is the standard value,
or the minimum value of the breaking load, while
the actual breaking load is the actual load during
testing.
The breaking load is determined by the nominal
tension of the wires making up the rope and is clas-
sified as shown in Table 2.
|
Standard 标准 |
Grade 破断强度 |
|
JIS G3525 日本 |
Grade E 1320N/mm2 135kgf/mm2 Grade G 1470N/mm2 150kgf/mm2 Grade A 1620N/mm2 165kgf/mm2 Grade E 1770N/mm2 180kgf/mm2 Special Grade 1910N/mm2 195kgf/mm2 |
|
European Standard DIN 欧洲 |
1370N/mm2 140kgf/mm2 1570N/mm2 160kgf/mm2 1770N/mm2 180kgf/mm2 1960N/mm2 200kgf/mm2 2160/mm2 220kgf/mm2 |
|
American Standard 美国 |
Traction steel Mild plow steel MPS Plow steel PS Improved plow steel IPS Extra Improved plow steel XIPS |
Ropes are usually of the bright type but when cor-
rosion resistant nature is required the ropes are
coated. Among the kinds of coating, there is the
zinc coating and aluminum coating. Generally, gal-
vanizing is commonly used.
Greasing
Rope grease is applied to the rope at the same
time of manufacturing to prevent corrosion and also
to provide lubrication. Great care is taken to apply
the rope grease uniformly and so that it will pen-
etrate to the core and strand, through an impreg-
nation method.