35WXK7 Non rotating Wire Rope
High Performance Steel Wire Ropes For All terrain cranes
All terrain cranes move heavy loads in dizzying working heights. For lifting loads at high radii, you need powerful and reliable high performance steel wire ropes as hoist ropes. In this context, efficiency and precision are paramount.
The main properties of our hoist ropes for all terrain cranes are high rotation resistance, highest efficiencies, high wear resistance and excellent spooling behavior in multilayer spooling.
Our compacted rotation resistant high performance steel wire ropes with their extremely high minimum breaking loads, high flexibility and very narrow diameter tolerances have successfully stood the test of time for decades. Of course, tested rope end terminations such as button sockets for commercially available pouch sockets, as well as tests and acceptance certificates are part of our product portfolio. Services like project planning, rope calculations and logistics handling round off our rope solution portfolio.
Your Ultimate Guide to Acquiring All Terrain Cranes Wire Rope
When purchasing wire rope for tower cranes, it’s essential to consider factors that ensure the rope’s performance, safety, and durability. Here’s a comprehensive guide to help you navigate through the process of acquiring the right wire rope for tower cranes:
Table of contents
Chapt 1
What is a steel wire rope, and how is it constructed?
A steel wire rope is an essential component in various heavy-duty industrial, construction, and marine applications, known for its high strength, durability, and flexibility. It’s specifically designed to handle demanding lifting and pulling tasks. Here’s a detailed look at what steel wire ropes are and how they are constructed:
What is Steel Wire Rope?
Steel wire rope is made from multiple steel wires that are twisted or braided together to form strands, which are then helically wrapped around a core. This design gives the rope its unique characteristics of strength, flexibility, and resistance to bending fatigue. The steel used is typically a high-carbon steel, which provides a good balance between abrasion resistance, fatigue resistance, and load-bearing capacity.
Construction of Steel Wire Rope
Materials: The wires used in steel wire ropes are usually made from high-carbon steel. The choice of material may vary depending on the specific requirements such as resistance to corrosion, heat, or wear. For enhanced corrosion resistance, stainless steel or galvanized steel might be used.
Strands: Several individual wires are twisted together to form a strand. The number of wires in each strand can vary, affecting the rope’s flexibility and strength. A common arrangement is a 6×19 class rope, which means each strand is made up of 19 wires, and there are 6 strands around the core.
Core: The core of a wire rope plays a critical role in maintaining its shape and providing support to the outer strands. The core can be:
- Fiber Core (FC): Made from natural fibers (like sisal) or synthetic materials. Fiber cores are more flexible but less supportive for the strands than steel cores.
- Independent Wire Rope Core (IWRC): This type is a smaller wire rope in itself and provides increased strength, durability, and resistance to crushing and heat.
Lay: The configuration of how the strands are twisted around the core is called the lay of the rope. Common lays include:
- Regular Lay: The wires in the strands and the strands in the rope are twisted in opposite directions. It is more stable and less likely to untwist.
- Lang Lay: Both the wires in the strands and the strands in the rope are twisted in the same direction, which provides better contact and wear characteristics but is more prone to kinking.
Lubrication: During manufacturing, the rope is lubricated to reduce friction among the wires and strands, which enhances fatigue resistance and protects against corrosion.
Properties and Applications
Due to their construction, steel wire ropes have high tensile strength, excellent flexibility, and significant resistance to bending and twisting. This makes them ideal for various applications such as:
- Cranes and hoists: For lifting heavy loads in construction and industrial settings.
- Elevators: As the main suspension element.
- Mining: For hoisting purposes in shafts.
- Marine applications: For towing, mooring, and anchoring.
Steel wire ropes are also subject to specific standards and regulations, which dictate their construction, testing, and application to ensure safety and reliability in their various uses. Proper maintenance, regular inspections, and adhering to usage specifications are crucial to maximize their lifespan and ensure safety during operations.
Chapt 2
How do steel wire ropes function in all-terrain cranes?
Steel wire ropes play a crucial role in the operation of all-terrain cranes, which are highly versatile mobile cranes designed to operate in various environments, from smooth paved roads to challenging off-road conditions. These cranes rely on steel wire ropes for several key functions that enable them to perform a wide range of lifting tasks. Here’s a detailed look at how steel wire ropes function in all-terrain cranes:
1. Lifting Operations
The primary function of steel wire ropes in all-terrain cranes is for lifting loads. The crane’s hoist mechanism uses these ropes to lift, lower, and suspend loads. The ropes are wound around a drum and, as the drum rotates under the power of the crane’s motor, the rope either winds or unwinds, raising or lowering the attached load. The strength and flexibility of steel wire ropes are crucial for handling the dynamic and static forces experienced during these operations.
2. Boom Extension
All-terrain cranes often feature telescopic booms that extend to reach higher or farther. Steel wire ropes are used within these boom sections to facilitate the extension and retraction process. As the ropes are drawn in, the boom extends; when the ropes are released, the boom retracts. The ropes must exhibit excellent fatigue resistance and flexibility given the frequent bending over sheaves and pulleys involved in this process.
3. Load Control and Stability
Steel wire ropes also contribute to the stability and control of the load. They can be part of the rigging arrangements that include slings, hooks, and other accessories, which help to secure the load and provide more control over its movement. This is essential in maintaining load stability, especially when the crane operates in windy conditions or on uneven terrain.
4. Slewing Operations
For the crane to rotate or slew the load, steel wire ropes may also be involved in transferring the mechanical power from the motor to the rotating part of the crane. These ropes need to sustain the torsional forces and resist abrasion as the crane turns around its vertical axis.
5. Safety and Emergency Functions
In some crane designs, steel wire ropes are integral to safety systems, such as brakes and emergency stop mechanisms. These ropes must be reliable and robust, as they are critical in emergency situations to halt operations safely.
Key Properties of Steel Wire Ropes for All-Terrain Cranes
- High Tensile Strength: To support heavy loads without breaking.
- Flexibility: To endure bending around pulleys and sheaves without excessive wear or fatigue.
- Abrasion Resistance: To withstand the wear from contact with various parts of the crane and environmental elements.
- Fatigue Resistance: To manage the stress from repeated bending and tension cycles.
- Corrosion Resistance: Especially important in varying environmental conditions where exposure to elements like moisture and chemicals can occur.
Maintenance and Inspection
Given their critical role and the severe conditions under which they operate, steel wire ropes in all-terrain cranes require regular maintenance and inspection. This includes checking for signs of wear, corrosion, kinking, and bird-caging, as well as applying lubricants to preserve their integrity and functionality.
By fulfilling these roles, steel wire ropes are indispensable to the operation of all-terrain cranes, enabling them to perform efficiently and safely across diverse operating conditions.
Chapt 3
What are the important specifications to consider when selecting a wire rope?
When selecting a wire rope for any application, including all-terrain cranes, it’s crucial to consider a set of specifications to ensure the rope is suitable for the task, durable, and safe. Here are the key specifications to evaluate:
Diameter
The diameter of the wire rope is one of the first specifications to consider. It must be appropriate for the load capacity of the crane and compatible with the sheaves and drums on the equipment. A rope that is too small may not handle the load safely, while one that is too large may not fit the machinery properly.
Construction
Wire rope construction refers to the arrangement and number of wires and strands. Common constructions include 35WXK7, and 19XK7,15xk7 etc, where the first number indicates the number of strands, and the second number indicates the number of wires per strand. The construction affects the rope’s flexibility, fatigue resistance, and how it handles bending stresses.
Core Type
The core is the center around which the strands are twisted. Cores can be fiber (natural or synthetic) or steel (independent wire rope core or wire strand core). Steel cores provide higher strength and resistance to crushing, while fiber cores offer more flexibility.
Lay Direction
Wire ropes are twisted in specific patterns called lays. Common lays are:
- Regular Lay: Strands are twisted in the opposite direction to the wires within the strands. It offers more stability and less rotation under load.
- Lang Lay: Both strands and wires are twisted in the same direction, offering better contact surface and wear characteristics but more prone to untwisting and kinking.
Tensile Strength
This is the actual calculated strength of the wire rope, often provided by the manufacturer, and it should exceed the maximum load expected to be placed on the rope during operations.
Breaking Strength
- Develop standardized procedures for the installation of wire ropes on tower cranes.
- Train crane technicians on proper installation techniques, including correct rope tensioning, anchoring, and spooling onto drums.
- Ensure that all installation procedures comply with manufacturer recommendations and industry best practices.
Flexibility
Flexibility is important for wire ropes that will be used on cranes with multiple sheaves or winches. More flexible ropes are generally easier to handle and better at withstanding repeated bending cycles.
Rotation Resistance
For lifting applications where the load should not rotate (such as when lifting prefabricated structures), rotation-resistant ropes are necessary to prevent the load from twisting.
Certifications and Compliance
Ensure the wire rope complies with relevant standards and regulations, such as those from the EN, ASTM, or specific industry guidelines. Compliance ensures that the rope meets certain safety and quality thresholds, Aulone can provide various standards and certifications.
By carefully considering these specifications, you can choose a wire rope that not only fits your operational requirements but also maintains safety and efficiency, prolonging the life of both the rope and the equipment it’s used on.
Chapt 4
All Terrain Crane Wire Rope Inspection and Maintenance
Regular inspection and maintenance of wire ropes on all-terrain cranes are essential to ensure safety, reliability, and longevity. Due to the varied environments and demanding conditions in which these cranes operate, having a structured approach to these practices is critical. Here’s how to effectively manage the inspection and maintenance of all-terrain crane wire ropes:
Inspection
Daily Visual Inspections
- Check for Obvious Defects: Look for visible external wear, broken wires, kinks, bird-caging, and any deformations.
- Assess Environmental Impact: Inspect for signs of corrosion or other environmental damage, especially if the crane operates in harsh conditions.
Periodic Detailed Inspections
- Schedule Regular Examinations: Conduct thorough inspections at intervals recommended by the manufacturer or based on the crane’s usage and operating environment. These should be performed by a qualified inspector.
- Use Non-Destructive Testing (NDT): Techniques like magnetic particle inspection, ultrasonic testing, or dye penetrant testing can be used to detect internal defects and assess the internal condition of the rope.
- Document Findings: Record and track any wear or damage trends, which can help predict when the rope might fail and should be replaced.
Operational Testing
- Load Test: Occasionally perform load tests under controlled conditions to ensure the rope can handle the rated capacity.
- Function Test: Check the smooth operation of the rope over sheaves and drums.
Maintenance
Regular Lubrication
- Apply Suitable Lubricants: Regularly apply lubricants appropriate for the specific wire rope and operating environment. This helps in reducing friction, protecting against corrosion, and extending the rope’s life.
- Method of Application: Ensure thorough application, penetrating to the core of the rope where possible. Follow the manufacturer’s recommendations for the type and frequency of lubrication.
Proper Handling and Use
- Avoid Misuse: Ensure that the rope is not overloaded, bent over sharp corners, or dragged along abrasive surfaces.
- Correct Spooling: Make sure the wire rope is correctly spooled on the drum to prevent overlapping and crushing.
- Monitor Rope Tension: Maintain proper tension to avoid slack that can lead to kinking or other damage.
Environmental Protection
- Storage: Store spare ropes in a dry, clean environment to prevent premature deterioration.
- Clean Ropes Regularly: Remove dirt, debris, and other contaminants that can accelerate wear.
Replacement Strategies
- Follow Manufacturer’s Guidelines: Adhere to the manufacturer’s guidelines regarding the service life and replacement criteria.
- Use Wear Indicators: Some ropes are equipped with wear indicators to help determine when a rope should be retired.
- Criteria for Replacement: Establish clear criteria for when a rope should be replaced, such as a certain number of broken wires per lay, severe corrosion, or visible damage like crushing or bird-caging.
Training
Operator and Maintenance Crew Education
- Training Programs: Conduct regular training sessions on proper rope handling, inspection techniques, and maintenance practices.
- Safety Practices: Emphasize the importance of safety and the proper response to potential rope failures.
By implementing a robust inspection and maintenance program, operators of all-terrain cranes can maximize the performance and lifespan of wire ropes, while maintaining the highest levels of safety and operational efficiency. Regular checks and diligent care are the best defenses against unexpected failures and accidents.
Chapt 5
All Terrain Crane Wire Rope Replacement and Recycling
Replacing and recycling wire ropes on all-terrain cranes are critical aspects of maintaining crane safety and operational efficiency. This process involves determining when a rope needs replacement, executing the replacement correctly, and disposing of the old rope responsibly. Here’s a detailed look at these processes:
Wire Rope Replacement
1. Assessment for Replacement
Regular Inspections: Utilize regular and thorough inspections to identify signs of wear, damage, or deterioration that meet the criteria for replacement, such as broken wires, severe abrasion, corrosion, or deformation like bird-caging or kinking.
Manufacturer’s Recommendations: Adhere to the manufacturer’s guidelines on rope life span based on usage and operational conditions.
Load Incident: Replace the rope if the crane has been involved in an overload incident, even if no visible damage is evident, as the internal structure could be compromised.
2. Planning and Preparation
Spare Ropes: Maintain a ready stock of appropriate wire ropes as specified for the crane’s make and model.
Qualified Personnel: Ensure that the replacement is conducted by skilled technicians who are trained in wire rope handling and crane mechanics.
Safety Protocols: Follow strict safety guidelines during the replacement process to protect workers from accidents.
3. Replacement Procedure
Removal of Old Rope: Safely unwind the old wire rope, ensuring that it is securely held to prevent uncontrolled movement.
Installation of New Rope: Install the new wire rope, carefully spooling it onto the drum to prevent overlaps and ensuring it runs smoothly over sheaves. Check for correct tension and alignment.
Initial Testing: Perform load tests and operational tests to verify the correct installation and functionality of the new rope before returning the crane to service.
Wire Rope Recycling
1. Assessment of Recyclability
Material Composition: Identify the materials used in the wire rope, typically steel, which is highly recyclable.
Contamination: Check for contaminants such as excessive grease or chemical residues that might need to be treated before recycling.
2. Collection and Sorting
Storage: Store discarded wire ropes separately from other waste to avoid contamination and ease the recycling process.
Sorting: Sort the ropes based on type and size, if necessary, to facilitate more efficient recycling.
3. Recycling Process
Transport to Recycling Facility: Arrange for the transport of the collected wire ropes to a metal recycling facility.
Processing: At the facility, wire ropes are typically cut into manageable lengths, cleaned if necessary, and then shredded or melted down for repurposing.
Reuse of Material: The recycled metal can be used in a variety of applications, including the production of new steel products.
Environmental and Regulatory Considerations
Compliance: Ensure compliance with local and national environmental regulations concerning waste handling and recycling.
Sustainability Practices: Encourage sustainable practices by participating in or initiating recycling programs that help reduce waste and promote the reuse of valuable materials.
Replacing and recycling wire ropes not only ensures the operational efficiency and safety of all-terrain cranes but also contributes to environmental conservation efforts by effectively recycling a valuable resource. It is essential for crane operators and maintenance teams to follow these procedures diligently to maintain high safety standards and promote sustainability.
Chapt 6
Common Questions
Frequently Asked Questions
The cost of our Aulone wire ropes varies depending on the specifications and quantity you require. Could you please provide more details so we can give you an accurate quotation?
Regarding warranties and after-sales services, rest assured, we offer comprehensive support. Our products come with a warranty, and we provide after-sales service to ensure your satisfaction. We are committed to maintaining the quality of our products and assisting you throughout the entire process.
500m is acceptable.
It's based on order size and customization requirements. Generally speaking, it is 30 days,However, we strive to fulfill orders as quickly as possible while maintaining our quality standards. For specific timelines, please reach out directly to our sales team.
Please provide wire rope structure, diameter, lay types, galvanized or ungalvanized, tensile strength, min breaking force, length of a roll, termination condition.
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