USHA MARTIN LIMITED2A, Shakespeare Sarani, Kolkata 700 071, India
Phone : 00 91 33 2282 3985, 39800300,Fax : 00 91 33 39800500/400
E mail : [email protected]
USHA MARTIN LIMITED2A, Shakespeare Sarani, Kolkata 700 071, India
Phone : 00 91 33 2282 3985, 39800300,Fax : 00 91 33 39800500/400
E mail : [email protected]
WIRE ROPE
No part of this Book may be reproduced, scanned, stored in a retrieval system ortransmitted in any form or by any means, electronic, mechanical, photocopying, recordingor otherwise, or reproduced on or by any disc, tape, perforated media or any otherstorage device or method without the permission in writing from Usha Martin Limited.
FOREWORD
Usha Martin Limited is a Speciality Steel and Steelproduct focused group with diverse product range inboth steel as well as wire rope.
It is one of the largest wire rope manufacturer in theworld. It is also the only wire rope company in theworld that has a totally integrated business model toconvert iron-ore into steel wire ropes as well as buildits own wire-drawing and rope-making machinery.
The steel wire ropes ranges from 1.5 mm to 140mmin size, 1370 to 2160 N/mm2 in grade andencompassing all constructions and all configurationslike Non-Compacted, Compacted, Plasticated, FlattenedStrand, Locked Coil ropes and slings.
Usha Martin ropes conforms to all specifications inthe world, viz. ISO, DIN, BS, IS, API, EN, AS, GOST,JIS and approved by all leading organisations, viz.ABS, API, DNV, LLOYDS, NKK.
Usha Martins rope works is one of the cleanest in theworld accreditated with TPM excellence award fromJapan Institute of Plant Maintenance.
It is one of the very few companies that has approvalby OTIS for its worldwide Elevator rope supply.
Usha Martin Steel wire ropes finds place in everycorner of the Globe and has presence in almost allapplication of ropes.
WIRE ROPE BASICS
54
WIRE ROPE COMPONENTS ROPE SIZE
n WIREn STRANDn CORE
CORE
KING WIRE
STRAND
WIRE ROPE
WIRES
Measure the circle just touching the extreme outerlimits (crown) of the strands.
INCORRECT
CORRECT
1 232
1 232
76
FUNDAMENTAL CONSTRUCTIONS FUNDAMENTAL CONSTRUCTIONS
CROSS LAY
EQUAL LAY
n Single-Wire centre with six wires of thesame diameter.
SINGLE LAYER
n Equal number of wires in each layer.
n All wires in each layer are of the samediameter.
n Large outer wires rest in the valley betweenthe small inner wires.
SEALE
n Inner layer having half the number of wiresas the outer layer
n Small filler wires, equal in number to theinner layer, are laid in the valleys of the innerlayer.
FILLER WIRE
n One diameter of wire in the inner layer.
n Two diameters of wire alternating large andsmall in the outer layer.
n The large outer-layer wires rest in the valleysand the smaller ones on the crowns of theinner layer.
WARRINGTON
n Combination of above constructions.Eg Seale-Filler, Warrington-Seale etc.
COMBINED
98
LAY IDEAL PULLEY GROOVE
Direction of Wire & Strand Helix Greater contact area between the rope and the pulley reducesabrasion and enhances service life.
RIGHT HAND REGULAR LAY (RHRL/RHO/sZ)
LEFT HAND REGULAR LAY (LHRL/LHO/zS)
RIGHT HAND LANGS LAY (RHLL/RHL/zZ)
LEFT HAND LANGS LAY (LHLL/LHL/sS)
ALTERNATE LAY (COMBINATION OF LANGS & REGULAR)
SPECIAL ALTERNATE LAY (2 LANGS 1 REGULAR)
WRONG
Sheave groove too narrow
WRONG
Sheave groove too wide
RIGHT
Sheave groove correctly supporting therope for 33% of its circumference
1110
PULLEY / ROPE BENDING RATIO(D/d RATIO)
Note:
The ratios are based on Max. rope speed of 60 meters/ min. For eachincrease of 30 mtrs/min. in excess of 60 meters per min., add 5% to thedrum diameter.
Shea
ve D
ia (D
)
Rope Dia (d) 1 6x7 (6-1) 64 422 6x19S (9-9-1) 48 323 6x26SW (10-5+5-5-1) 45 304 6x25F (12-6F-6-1) 39 265 6x31SW (12-6+6-6-1) 39 266 6x37SF (12-12-6F-6-1) 39 267 6x36SW (14-7+7-7-1) 33 228 6x43SF (14-14-7F-7-1) 33 229 6x50SFS (14-14-7F-7-7-1) 33 22
10 6x41SW (16-8+8-8-1) 30 2011 6x49SW (16-8+8-8-8-1) 30 2012 6x49SF (16+16+8F-8-1) 30 2013 6x46SW (18-9+9-9-1) 27 1814 6x52SW (18-9+9-9/6-1) 27 1815 6x55SF (18-18-9F-9/6-1) 27 1816 8x19S (9-9-1) 39 2617 8x26SW (10-5+5-5-1) 36 2418 8x25F (12-6F-6-1) 33 2219 8x31SW (12-6+6-6-1) 33 2220 8x37SF (12-12-6F-6-1) 33 2221 8x36SW (14-7+7-7-1) 29 1922 8x50SFS (14-14-7F-7-7-1) 29 1923 17x7 (11:6-1) 52 3424 18x7 (12:6-FC) 52 3425 19x7 (12:6-1) 52 3426 34x7 (17:11/6-FC) 45 3027 35x7 (16:6+6-6-1) 61 4028 6x25FS (12/12/ ) 48 3229 6x8FS (7/ ) 73 4830 6x28FS (15/12/ ) 45 3031 Locked Coil Winding Rope 152 100
Sl. No. Construction
D : d Ratio
MinimumRecommended
1312
FLEET ANGLE SPOOLING/ANCHORAGE OFROPE ON DRUM
n Ropes are supplied with zero internal torque
n Improper spooling induces torque in rope, reducingthe rope life.
A B
OVERWINDLeft to Right
USE RIGHT LAY ROPE
UNDERWINDRight to Left
USE RIGHT LAY ROPE
UNDERWINDLeft to Right
USE LEFT LAY ROPE
OVERWINDRight to Left
USE LEFT LAY ROPE
C D
Note:
Recommended angleGrooved drum : 2.5O
Flat drum : 0.5O 1.5O
Angleof Fleet
Centre lineof Reel
Centre Lineof Sheave
L RL R
L RL R
1514
ROPE CUTTING PROCEDURE ROPE CLAMPING
n Seizingn Twistingn Cutting
Note:
Seizing wire recommendation- for ungalvanised rope use annealed wire- for galvanised rope use soft, zinc-coated wire.- Diameter of wire: 8 - 24 mm = 1 mm
26 - 36 mm = 1.6 mm38 - 56 mm = 2 mm
- Recommended seizing length = 1 x d min or 10 wraps
The Right Way to Clip Wire Rope
The Wrong Way to Clip Wire Rope
Note:
Improper fixing of clamps may lead to safety hazards.For proper clamping practice, refer applicable standards or OEMrecommendations.
1716
IN-USE LUBRICATION IN-USE LUBRICATION
POURING
n Usha Martin Ropes are supplied with special lubricant
n Periodic Lubrication during usage is necessary to deriveenhanced performance.
CONTINUOUS BATH
SPRAY NOZZLEPAINTING
SWABBING
As Manufactured
100%
140%
As Manufactured + In-service Lube
Life Enhancement
DRIPPING
In-use lubrication pays rich dividend
1918
STORAGE HANDLING THE RIGHT WAY
n Must be stored in a well ventilated shed.
n Free from moisture, dust and fumes.
n Suitable lubricant to be applied every3 months to the outer layers.
n Reel containing ropes to be rolled through 90 degreeafter every 3 months
n Protect wooden reels from the attack of termites.
n In no case the reels should be put on ground oruncemented floor.
n Use spindle through the reels for loading / unloading or putthe rope on a swift with brake arrangement.
n Allow clearance for free rotation of reel when the rope endis pulled.
n Maintain constant tension during haul off.
n Prevent crossing of rope laps on the reel.
n Avoid possible kink, which is a permanent damage to a rope.
GROUND CLEARANCE
COVER / SHED
2120
HANDLING THE RIGHT WAY WIRE ROPE CHARACTERISTICS
BEND FATIGUE & ABRASION RESISTANCE
n More wires better fatigue resistance
n Less wires better abrasion resistance
Rope resistance to bending
Rope resistance to abrasion
6
9
10
12
12
12
14
16
18
6 x 7
6 x 19S
6 x 21F
FlattenedStrand
6 25FW
6 x 31WS
6 x 36WS
6 x 49WS
6 x 61WS
LEAST RESISTANCE TO BENDING FATIGUE GREATESTLEAS
T R
ESIST
ANCE
TO
AB
RASIO
N G
REAT
EST
2322
WIRE ROPE CHARACTERISTICS WIRE ROPE CHARACTERISTICS
COMMONLY USED ROPE (Non-compacted)CHARACTERISTICS SIMPLY STATED
COMPARISON OF ROTATION RESISTANCE
n More wires in the outer strand (14 for 36WS) will improvebend fatigue
n Less wires in the outer strands (9 for 19S) improvewear/abrasion resistance characteristics
n Steel core (IWRC) resists drum crushing better thanfibre core
n Langs lay resists interference at drum better thanordinary lay
Abrasion ResistanceComparison of outer wire sizes for 25 mm diameter rope,as illustration
6 x 7 6 outer wires 2.54mm6 x 19S 9 outer wires 2.11mm6 x 25F 12 outer wires 1.70mm6 x 36 14 outer wires 1.49mm6 x 41 16 outer wires 1.34mm
Turn
Load
Parallel closed ropes (eg. Powerform 8PC)
6/8 strand ropes (eg. Hyflex 6)
Low rotation ropes (eg. Hyflex 18)
Rotation resistant ropes(eg. Powerform 35)
0
6 x 19 Class
8 x 19 Class
Hyflex & Powerform18
Hyflex & Powerform 35
Rope Tension 15%x MBL
20%x MBL
Rotation(deg/m)
2524
WIRE ROPE CHARACTERISTICS WIRE ROPE CHARACTERISTICS
COMPACTED ROPESCHARACTERISTICS SIMPLY STATED
n Increased breaking force
n Increased performance
n Improved characteristicsl Improved wear resistancel Improved crushing resistancel Improved Bend Fatigue resistance
Compacted ropeminimum breaking force
Conventional rope minimumbreaking force
=
Line Contact Surface Contact
High Abrasion Resistance
CompactedConventional
Internal Contacts
External Contacts
High Breaking Load per uni
