How to maximize the service life of wire rope?

How to maximize the service life of wire rope?

In order to maximize the service life of wire rope, scientific management and operation are required from the aspects of selection, installation, use, maintenance and scrapping. Here are some key measures:

1. Correct selection:
Choose the appropriate wire rope type, specification and strength grade according to the working conditions. Consider factors such as load size, lifting speed, operating frequency, environmental corrosion degree, bending number and diameter ratio (ratio of wire rope diameter to pulley or drum diameter). Ensure that the actual breaking tension of the wire rope is greater than the safety factor requirement of the working load. Different application areas have different safety factor standards.
Choose wire ropes produced by manufacturers with reliable quality and good reputation.

2. Standard installation:
Avoid damaging the wire rope during installation. Use the correct tools and methods for laying, threading and connecting. Ensure that the wire rope is wound neatly on the drum to avoid random winding, overlapping and squeezing.
Ensure that the rope groove size, shape and surface finish of the pulley and drum match the wire rope to reduce friction and wear. The radius of the rope groove should be slightly larger than the radius of the wire rope. Auxiliary devices such as guide wheels and rope pressure wheels should be reasonably set to avoid excessive bending and scratching of the wire rope. Ensure that the end connection of the wire rope is reliable and firm and can withstand the working load. Check the wear and looseness of the connector regularly.

3. Correct use:
Avoid overload operation. Operate strictly in accordance with the design load of the equipment. Start and brake smoothly to reduce impact loads. Avoid the wire rope being in a torsion state for a long time. Reasonably control the rotation and movement of the lifting mechanism. Avoid friction or extrusion between the wire rope and other objects. Check the working state of the wire rope regularly and deal with abnormalities in time.

4. Scientific maintenance:
Lubricate regularly. Choose a suitable lubricant according to the type of wire rope, working environment and temperature. The purpose of lubrication is to reduce friction between steel wires, prevent rust, and extend the life of the inside and outside of the wire rope. Use the correct lubrication method to ensure that the lubricant can penetrate into the inside of the wire rope. Common methods include manual oiling, dripping oil lubrication and pressure injection lubrication.
Establish a sound inspection system, clarify the inspection cycle, inspection content and responsible persons.

The inspection content includes the wear of the wire rope, the number of broken wires, deformation (such as twisting, flattening, birdcage), corrosion, diameter reduction, lubrication condition and the condition of the end connectors.
For key parts (such as the parts in contact with the pulley and drum, and the end connection), key inspections should be carried out. Record the inspection results, and evaluate and deal with the defects found. For wire ropes that reach the scrap standard, they must be stopped and replaced immediately. Store spare wire ropes properly to avoid direct sunlight, rain and humid environments. Take protective measures during transportation to prevent damage to the wire rope.

5. Timely scrapping:
Strictly implement the scrapping standards for wire ropes. When the wear, number of broken wires, deformation or corrosion of the wire rope reach the specified scrap index, it must be replaced in time and must not be used beyond the expiration date to ensure safety.