Objective
The aim of these studies was to permit evaluation of rope behaviour in realistic conditions on crane installations and hence improve safety at crane workplaces in the steel industry.
The main focus of the present work was on tests carried out on a testing rig with a selected rope type subjected to dynamic loads of different amplitudes and frequencies. Different incoming and outgoing rope angles were produced on various sheaves, with a dynamically varying angle of fleet on one sheave.
Tests with dynamic rope loading revealed fundamental differences in the operating behaviour of the rope compared with static tests. The wear mechanisms causing damage differ depending on the loading. The smaller the loading-limit ratio, the lower the proportion of outwardly visible rope damage, with wire breakages shifting to the inside of the rope. The rope deteriorated rapidly following the occurrence of the first visible wire breakages.
For operators of crane installations, the shifting of damage to the inside of the rope as a function of dynamic loading and the reaching of discard limits shortly after the first signs of wire breakages are of particular interest. In view of these findings, the monitoring of rope drives in crane installations with a high alternating load component in relation to the mean load should be intensified compared with installations with a more uniform loading. The load sequences used in the test programme comprised blocks of sinusoidal oscillations separated by periods of constant load. This approximation to the operating conditions of crane installations ensures reproducibility and provides fixed parameters.
In crane installations in the steel industry, wire ropes are subject to severe stress in unfavourable environmental conditions (e.g. heat). In such conditions, the dimensions of running wire ropes cannot be maintained indefinitely. The rope drives of crane lifting gear therefore require special checks, i.e. visual inspections of the rope surface. The surface life of wire ropes is often only a few months, and the costs of rope replacement are considerable. In addition to the cost of the rope itself, account needs to be taken of the high wage costs, while additional costs are often incurred by the loss of production. In recent years, a number of cases of rope damage have been documented where no visible signs indicating that the rope should be discarded were discernable despite regular inspection. Such events are unacceptable for safety reasons and must at all costs be avoided with crane ropes. The cause of damage was assumed to be dynamic influences on the rope loading. As there have so far been no studies of the effects of dynamic rope loading and dynamic off-groove running on rope life, a test installation was constructed from an existing test rig in order to carry out extensive tests on the behaviour of crane ropes with dynamic loading. In order to model realistic operating conditions, operating parameters for crane installations were determined in extensive studies. The evaluation of these parameters and influencing factors was a central part of the research.
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Programme(s)
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Coordinator
47057 Duisburg
Germany
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