Inventor’s Corner
Locked Coil Wire Rope and Capacity Expansion Framework
A locked coil wire rope includes a circular steel wire inner layer, a central metal core, and a Z-shaped steel wire outer layer. The central metal core has a structure of 1x19W, 1x19S, 1x26WS, 1x31WS, 1x31SW, 1x49SWS or 1x55SWS. The circular steel inner layer includes at least two circular steel wire layers, and a number of steel wires of circular steel wire layer is no less than 18. The Z-shaped steel wire outer layer includes at least one Z-shaped steel wire layer, and a number of steel wires of the Z-shaped steel wire layer is no less than 51. A capacity expansion framework is further disclosed.
Figure 15 is a schematic diagram of a locked coil wire rope according to an embodiment. In the embodiment as shown in figure 15, a locked coil wire rope includes more than 100 steel wires and has a diameter larger than 80 mm. Specifically, the locked coil wire rope includes a circular steel wire inner layer, a central metal core and a Z-shaped steel wire outer layer. The central metal core includes 19 steel wires 3 with a structure of 1x19W or 1x19S. The circular steel wire inner layer includes seven circular steel wire layers formed from a plurality of steel wires 2. The Z-shaped steel wire outer layer includes three Z-shaped steel wire layers formed from a plurality of Z-shaped steel wires 1. The number of steel wires 2 is 18 or more and Z-shaped the number of steel wires 1 is 51 or more.
In an embodiment, the diameter of the locked coil wire rope is 130 mm, and the structure of the central metal core is 1x31WS. The circular steel wire inner layer optionally includes seven circular steel wire layers, and the steel wires of the seven circular steel wire layers, from the inside out, is in a 18+24+30+36+42+42+48 form (i.e., seven steel wire layers consisting of a layer of 18 steel wires, a layer of 24 steel wires, … and a layer of 48 steel wires). The Z-shaped steel wire outer layer optionally includes three Z-shaped steel wire layers, and the steel wires of the three Z-shaped steel wire layers, from the inside out, is in a 57+64+71 form. For specific applications, the structure of the central metal core can be 1x31SW, and the structure of steel wires of the locked coil wire rope, from the outside out, is optionally in a 71Z6+64Z6+57Z6+48+42+42+36+30+24+18+31SW form.
In an embodiment, the diameter of the locked coil wire rope is 120 mm, and the structure of the central metal core is 1x31WS. The circular steel wire inner layer optionally includes six circular steel wire layers, and the steel wires of the six circular steel wire layers, from the inside out, is in a 18+24+30+33+39+45 form. The Z-shaped steel wire outer layer optionally includes three Z-shaped steel wire layers, and the steel wires of the three Z-shaped steel wire layers, from the inside out, is in a 51+58+65 form.
In the above embodiments, the central metal core and the circular steel wire inner layer individually have a tensile strength of 1870 MPa or more, and the Z-shaped steel wire outer layer has a tensile strength of 1770 MPa or more. A surface of the locked coil wire rope has a zinc-aluminium alloy coating with an aluminum content of more than 4.2% and a coating weight of more than 255 g/m2. The surface of the zinc-aluminium alloy coating is uncoiled. When implemented in this manner, the steel wires for the locked coil wire rope may be pre-coated.
By way of example, a method of manufacturing the locked coil wire rope with a diameter of 130 mm includes the following steps: (1) Manufacture of Zinc-Aluminum Alloy-Coated Steel Wires; Processing parameters of the zinc-aluminum alloy-coated steel wires: drawing steel wires with steel grade 82B; DV value: 120; diameter: 2.0-8.0 mm; zinc temperature: 440+/-50°C; zinc-aluminum alloy temperature: 450+/-50°C; working speed: 22 m/min for diameter of 2.58-3.05 mm; 16 m/min for diameter of 4.03-5.15 mm; and the thickness of zinc coating and aluminum content meet requirements of Class A of GB/T20492-2006 standard “Zinc-5% aluminum mischmetal alloy-coated steel wire and steel wire strand”.
(2) Manufacture of Locked Coil Wire Rope; Qualified zinc-aluminum alloy-coated steel wires are used to strand a core of 1x31SW on a tubular strander. A single strand of a circular wire then is separately stranded with a series of units. Finally a three-layer Z-shaped steel wire is closed using a closer. A wire separator is used in stranding and closing-up processes. Diameters of die holes of stranding dies are slightly smaller than the diameters of the strand and the steel wire rope by 0.5-2.0 mm. During stranding process, the tension of each wire is ensured to be even so that the steel wire rope is stranded tightly. The manufactured ZZZ-j 130 mm zinc-aluminum alloy-coated locked coil wire rope has been tested by Testing Center, and all parameters meet the relevant standards and design requirements, which is suitable for spatial structure, large stadiums, tourism cableway, deep winding and other applications and is more competitive in the market. It should be understood that in some embodiments, the structure of the central metal core of the locked coil wire rope may be 1x26WS, 1x49SWS or 1x55SWS.
Figure 16: Front view of a capacity expansion framework.
In the manufacture of the above locked coil wire ropes, the central metal core is produced with the tubular strander in a one-stranding manner. A circular steel wire layer is then stranded with a series of multi-frame units by one stranding to form the circular steel wire inner layer. Finally, the Z-shaped steel wire layer is stranded layer by layer on a planetary closer. In specific implementations, the planetary closer may include six, eight or ten frames and each frame is provided with at least two spools.
Since traditional closers can only accommodate a single large spool, an embodiment of the present invention further provides a capacity expansion framework to replace the traditional large spools. The capacity expansion framework is capable of producing the above locked coil wire ropes. By way of example, as shown in figures 16 and 17, the capacity expansion framework according to an embodiment of the present disclosure includes a plurality of spools 20, a plurality of spool axles 30 and a framework body 10. The plurality of spools 20 are fixed on the framework body 10 through the plurality of spool axles 30. Each of the spool axles 30 is fixed through a gland 4, a screw and a nut 6. The framework body 10 is further provided with a plurality of braking devices 5, a thimble sleeve 7 and at least one roller 8.
Figure 17: Top view of a capacity expansion framework.
The braking devices 5 are used to brake the respective spools 20. Twelve spools 20 are arranged in two vertical layers, each layer including six spools 20 arranged in two rows and three columns cooperating with the corresponding roller 8. The thimble sleeve 7 is arranged between the two vertical layers. Particularly, the capacity expansion framework is assembled as follows: installing the spools 20 on the framework body 10; passing the spool axles 30 through center holes of spools 20; pressing the spool axles with the glands 4, and fixing the spool axles with the adjustable screws and nuts 6 to prevent the spools 20 from moving.
The spools 20 adjust a tension through the braking devices 5 while paying off wires and the wires from the spools 20 are evenly distributed through the rollers 8. In specific implementations, the above capacity expansion framework may replace the spools of the traditional closer. With overall dimensions for mounting unchanged, the number of spools 20 is increased and the arrangement and size of the spools 20 are adapted to ensure the dynamic stability and even paying off during transmission of the framework. A form of framework-in-framework allows the capacity expansion framework to strand large-diameter wire rope with over 100 steel wires and the outermost layer steel wire of the locked coil wire rope with a diameter larger than 80 mm. The number of the spools 20 may be altered according to the specifications of the locked coil wire rope, and optionally the number of the spools 20 is 6 to 14. Further, with the use of the wire separator, the locked coil wire rope as of various specifications can be stranded. This breaks the bottleneck in capacity and production capability of traditional equipment, improving the efficiency of producing the locked coil wire ropes.
Pat. 10,640,919 U.S. class 1/1 Int. class D07B 1/06
Inventor: Zhongqu Huang, Guizhou, CN., Xiaogang Wang, Guizhou, CN., Xiaoyu He, Guizhou, CN., Zhiyuan Yan, Guizhou, CN., Nan Xia, Guizhou, CN.
Assignee: Guizhou Wire Rope Incorporated Co., Zunyi, CN.
