钢丝绳联轴器的性能试验及数学模型

对钢丝绳联阵器进行了动刚度性能实验，在此基础上建立了数学模型，并进行了参数辨识，指出钢丝绳联轴器具有强非线性，对减小轴系统扭转振动具有良好的效果。     

钢丝绳弹性联轴器特性建模

提出一个钢丝绳弹性联轴器特性的数学模型，该数学模型能很好地描述钢丝绳弹性联轴器的迟滞非线性特性。分析表明，钢丝绳弹性联轴器具有软刚度和阻尼大的特性，有利于抑制船舶轴系的振动。     

高弹联轴节轴系在简谐激励下非线性振动的稳态解

本文研究了具有非线性迟滞性恢复力高弹性联轴器轴系在简揩激励下求解非线性振动稳定周期解的问题，建立了该转子轴系的数学模型，并采用高量谐波平衡法从理论上导出求解轴在简谐激励下的非线性振动稳定周期解的一种迭代算法，最后利用该算法分析钢丝绳高弹性联轴节轴系在简谐激励下的非一振动的稳定周期解，并讨论非线性迟滞恢复力对轴系非线性振动的影响。     

钢丝绳成形力学行为的非线性有限元分析

钢丝绳捻制成形过程属于三维梁大转动弹塑性变形问题。钢丝绳的加工应力不仅影响成形性，而且由其引起的残余应力对钢丝绳结构强度有很大影响。为保证钢丝绳成形模拟计算精度和效率，从而为钢丝绳成形工艺与结构强度的合理设计提供依据，本研究建立了考虑大转动几何非线性和材料非线性的共转坐标系弹塑性有限元计算基本方程，在此基础上编制了钢丝绳成形过程模拟计算程序。通过数值模拟计算分析钢丝绳捻制成形过程的反扭转系数对加工应力应变分布和残余应力的影响，计算结果表明：反扭转系数对捻制成形过程中应力应变和残余应力及形状冻结性有显著影响，合理的反扭转系数应取略大于1.0的值。实验结果证实了本文提出的捻线成形过程数值模拟几何模型和有限元计算模型的有效性。     

深水勘察船基盘被动升沉补偿系统的设计研究

在深水勘察船升沉运动时,为使牵引基盘钢丝绳的拉力保持在一定的范围,设计了基盘被动升沉补偿系统．介绍了基盘被动升沉补偿系统的方案和工作原理,建立了基盘被动升沉补偿系统的数学模型,分析了钢丝绳对分析部件的拉力．对补偿系统中的滑轮组倍率、液压缸直径、液压缸行程和蓄能器总容积这4个主参数进行了分析设计,并分析了补偿系统中钢丝绳对基盘的拉力．最后针对具体的勘察船升沉运动和作业水深的设计条件以及钢丝绳对基盘的拉力范围的设计要求,通过对补偿系统中的一些设计参数的取值,对补偿系统中的主参数进行了设计计算,并对设计的补偿系统中钢丝绳对基盘的拉力进行了仿真．仿真结果表明,钢丝绳对基盘的拉力达到了设计要求．这为相关设计人员对基盘被动升沉补偿系统的设计提供了理论指导．     

变质量提升系统钢丝绳轴向-扭转耦合振动特性

为了掌握变质量提升系统的振动特性,考虑提升钢丝绳的扭转运动并根据变质量非完整系统的Ham ilton原理建立了钢丝绳轴向和扭转耦合振动数学模型,并推导了变质量提升系统振型函数及确定轴向与扭转耦合振动频率的超越方程,给出了基于振型函数随系统质量变化及固定不变两种情况下变质量提升系统钢丝绳振动位移、张力和扭矩响应的求解方法。以矿井提升箕斗装载为工况进行应用分析,结果表明:两种求解方法得到的响应基本接近;提升容器装载过程是一个质量增大振动频率减小的过程,钢丝绳的动位移、张力和扭矩以波动形式逐渐增加。装载量较大时可采用振型函数固定的方法计算装载提升系统的频率和响应,冲击较大的载荷建议考虑提升容器的波动载荷,从而有助于提高计算效率和增强提升系统的安全可靠性。     

浅析钢丝绳电动葫芦的技术现状及前景

钢丝绳电动葫芦作为一种轻小型起重设备，广泛应用于国民经济各个领域。CDI型钢丝绳电动葫芦在国内生产制造、使用已达近40年的历史。本文分析了我国钢丝绳电动葫芦行业的现状，重型钢丝绳电动葫芦存在的诸多不足，指出我国钢丝绳电动葫芦行业发展的未来方向。     

焦家金矿应用TCK检测技术进行钢丝绳安全管理的创新实践

钢丝绳广泛应用于国民经济的多个重要领域,多年来钢丝绳在使用过程中始终存在安全隐患突出、经济性差、事故危害大等世界性难题。目前,国内矿山企业还一直沿用人工检测方法进行钢丝绳安全管理,造成企业多年来提升运输事故不断,损失十分巨大。焦家金矿根据当前矿用钢丝绳使用现状,结合自身实际和钢丝绳使用经验,引用先进的TcK弱磁检测技术对在用钢丝绳进行科学定量检测,并率先在国内同行业建立钢丝绳在线实时监测系统,在钢丝绳科学、安全使用方面进行了富有成效的探索。     

三峡升船机钢丝绳断丝与磨损检测原理及实现

根据三峡升船机钢丝绳的使用特点，提出了三峡升船机钢丝绳检测的原理与方法，采用周向多回路对钢丝绳轴向励磁，利用漏磁场原理检测钢丝绳断丝，磁桥回路检测钢丝绳磨损量，并实现在一个传感器中对断丝和磨损两种缺陷信息的综合检测。在信号处理方面设计了相应的电路和软件，实现了缺陷的定量分析。     

超深矿井提升机卷筒动态应力与疲劳寿命研究

超深矿井提升机卷筒在钢丝绳多层缠绕时所受钢丝绳的缠绕力错综复杂,在长期作业过程中卷筒结构可能会萌生裂纹进而发生疲劳破坏,所以有必要对卷筒结构在多层缠绕实际工作条件下的疲劳寿命展开研究。基于板壳理论,将超深矿井提升机卷筒视为均匀受压的旋转对称壳体,通过对卷筒结构负荷构成进行分析,建立了钢丝绳对卷筒作用力的数学模型,并根据提升系统动力学原理建立了钢丝绳满载上提和空载下放的动力学模型,确定了卷筒结构的动态载荷。通过对卷筒结构作业过程强度分析得出卷筒结构在整个工作循环中的应力-时间历程曲线。结合不同存活率的S-N曲线和累积损伤理论,分析了卷筒结构在不同负载下的疲劳寿命。研究结果表明：提升机满载上提和空载下放过程中卷筒结构的最大等效应力均出现在等速阶段,且其最大等效应力出现在卷筒内壁支轮与支环的中部;在给定的存活率下卷筒结构的疲劳寿命与工作负载密切相关。研究结果为多层缠绕复杂工况下卷筒的力学分析与科学设计提供了理论支撑。     

Bending fatigue behaviour of bearing ropes working around pulleys of different materials

Nondestructive quantitative detection and artificial detection were carried out to study bending fatigue behaviour and failure mechanisms of wire ropes. When working around nylon pulleys, wire ropes exhibit a slowly increasing of fracture rate and total damage in one lay length. The bending fatigue life of wire ropes is twice longer than that of ropes working around steel pulleys. The primary failure mode of wire ropes working around nylon pulleys is fatigue fracture and the fracture surfaces of wires exhibit a wide crack propagation zone and narrow tear zone.     

小波分析在钢丝绳无损检测中的应用

目前钢丝绳无损检测中对断丝信号的处理仍比较困难，小波分析可以聚焦到信号的不同细节，于是本文将它应用于断丝信号的消噪平滑和奇异性检测，使得信号更加光滑，消除了干扰信号，避免断丝误判，同时使奇异点更加明显，有效地提高内外部断丝识别和定量检测的准确率，实验证明该方法效果明显。     

通用桥式起重机钢丝绳断裂失效分析

为查明某玻璃厂一台通用桥式起重机钢丝绳断裂导致货物坠落的事故原因,对断裂的钢丝绳进行了理化检验,并对钢丝绳滑轮组和防跳绳安全保护装置的结构进行了分析。结果表明：钢丝绳断裂为挤压磨损致使钢丝绳不能承受较大载荷而产生的一次性大应力断裂,导致事故的直接原因是防跳绳安全保护装置的结构设计存在严重缺陷,使钢丝绳脱出滑轮槽在轴衬套上运行,产生较大的滑动摩擦力,使钢丝绳磨损变形。     

Microstructural manifestations of fractured Z-profile steel wires on the outer layer of a failed locked coil wire rope

Locked coil wire ropes, by virtue of their unique design and construction, have specialized applications in aerial ropeways, mine hoist installations, suspension bridge cables, and so forth. In such specialty ropes, the outer layer is constructed of Z-profile wires that provide not only effective interlocking but also a continuous working surface for withstanding in-service wear. The compact construction and fill-factor of locked coil wire ropes make them relatively impervious to the ingress of moisture and render them less vulnerable to corrosion. However, such ropes are comparatively more rigid than conventional wire ropes with fiber cores and therefore are more susceptible to the adverse effects of bending stresses. The reasons for premature in-service wire rope failures are rather complex but frequently may be attributed to inappropriate wire quality and/or abusive operating environment. In either case, a systematic investigation to diagnose precisely the genesis of failure is desirable. This article provides a microstructural insight into the causes of wire breakages on the outer layer of a 40 mm diameter locked coil wire rope during service. The study reveals that the breakages of Z-profile wires on the outer rope layer were abrasion induced and accentuated by arrays of fine transverse cracks that developed on a surface martensite layer.     

Electromagnetic testing,a reliable method for the inspection of wire ropes in service

The art of wire rope inspection has progressed rapidly over the past few years. Presently available electromagnetic instruments are now much easier to operate and provide an important (in some cases indispensable) element of wire rope inspection. Test data obtained from these instruments can provide accurate quantitative estimates of safety-related wire rope parameters such as loss of metallic cross-sectional area (LMA) and provide a more reliable basis for estimating the condition and remaining service life of a rope. This paper illustrates the use of modern nondestructive test methods to assess the safety of wire ropes in service.     

Theoretical and experimental investigation of effects of failures on the tensile endurance of elevator ropes

Elevators have an important place in human life just after uprising demands in high rise buildings, skyscraper and luxury residence concepts have surged. Steel wire ropes provide permanent working safety and reliability in the elevator installations. Due to this reason steel wire ropes are one of the vital components of elevators. In this study, effects of discard criteria such as wire breaks, abrasive wear and corrosion where extents of those failures are defined by ISO 4344 standard on the tensile endurance of 6×19 Seale and 8×19 Warrington elevator ropes have been investigated theoretically and experimentally. Tensile endurances of rope samples that have different extents of failure have been determined by using tensile testing machine and comparison is made by undamaged samples for each rope separately. In addition, stress and strain values occurred on the elevator ropes investigated have also been presented. The most critical failure type has been found to be 24 wire breaks for 6×19 Seale rope with fiber core where lifting capacity reduced by 25.99 %. The most critical failure type has been found to be abrasive wear which is 0.1 mm in depth along 100 mm length for 8×19 Warrington rope with independent wire rope core where lifting capacity reduced by 7.93 %.     

Theoretical approach to the solutions of axially loaded complex ropes

Abstract

A rational analysis procedure consisting of a complete cycle of systematic calculations has been developed for the theoretical solutions of problems in describing the behavior of axially loaded complex ropes consisting of wires and strands, which were simulated as particle‐motion models. In essence, axial and rotational strains of a rope were specified. Constitutive relations of the loaded wires and strands were obtained through compatibility of motion requirements. Material law was then imposed to determine the internal force of each wire. Nonlinear equilibrium relations of wires were applied to describe the relationship among sectional stresses and external forces. The theory is used in the analysis of a 6 × 7 wire rope with an independent wire rope core (IWRC). Some solutions and comparisons to other research results have been provided. Results show that the recursive nature of the wire in the model enhanced the calculation of constitutive relations and made it easier to apply to the analysis of complex ropes having multiple orders.     

向家坝水电站A型塔架式缆机安装技术

向家坝缆机为国内跨度最大的A型塔架式缆机,A型塔架自升时安全风险较大,主索过江难度大,具有一定的安装技术要求。本文主要介绍了缆机安装的各个程序和步骤,重点介绍了A型塔架的安装、顶升、自升和绳索系统的安装调试,供各位同仁参考借鉴。     

Failure Analysis of Wire Rope Used for Hoisting in Mining: A Case Study

Wire ropes are used in vast range of applications and many of the applications are safety critical. In the mining industry wire ropes are extensively used for hoisting/haulage. Due to the hostile operating load conditions, many wire ropes degrade in service. Fatigue of wires in rope in combination with other detrimental factors is frequently responsible for rope deterioration and premature failure during operation. In this paper the causes of failure of a wire rope used for hoisting in an Indian mine are determined with only a minimum level of information provided by the customer. Samples of the failed rope were obtained and analyzed and potential remedial measures to prevent such degradation are discussed. Reprinted with permission from Proceedings of AIME 2006, held on January 20–21, 2006 organized by Jamia Milia Islamia (a central university) New Delhi-110025, pp. 122–132.