Illustration of Point Contact and Line Contact Cables. A, Point Contact Cable; B, Line Contact Cable

b. One-line grab

The single-wire grab bucket is suspended on a single cable 1 with a hook ring that connects with the hoisting machine's hook. The bucket is lowered into the pile of material in the open state (Case II, Figure 1.16), at which time the movable head 8 rests on the upper support head 2. Under the effect of the bucket's weight, the bucket blade 4 is deeply embedded in the pile of material. Cable 1 continues to move down and under the effect of the weight of the movable head 8, the hook 9 connects with the lower support head 6 (Case II, Figure 1.16). When cable 1 is pulled up, the bucket's jaw closes to carry out the material loading process. The bucket with the material is sealed and continues to be lifted to the position where the material needs to be unloaded.



Figure 1.16: Single-line grab bucket


When it is necessary to unload the material, the lever 10 must be pushed into the stop bar 7 fixed at the height at which the material needs to be unloaded. Thus, the single-rope grab can be mounted on any type of lifting machine as long as it has a cable drum and cannot unload the material at any height.

1.4. Rope in lifting mechanism

Wires are understood as elements with a very small cross-sectional area compared to their length. Soft is understood as being easily bent in all directions, not soft and hard (measured in HB) as in Materials Science. Soft wire is understood as an element that is soft and has a certain stiffness .

a. Concept

In lifting machines, soft ropes are used to: Connect the lifting object to the lifting mechanism; Connect this object to that object and used for lashing.

b. Classification

- Synthetic cable: Endless source of raw materials, high tensile strength, less affected by the environment. Good elasticity, no need to be moisture-proof, but high cost and quickly ages over time.

- Steel cable: High tensile strength, resistant to friction, relatively low specific gravity, susceptible to corrosion...

- Plant cable: Soft, light, tough, low tensile strength, but poor abrasion resistance, high moisture absorption, swells when soaked in water, slow to dry.

- Welding chain: Large specific gravity sensitive to impacts

- Hinge chain: Often used in transmission

In lifting machines, steel cables and welded chains are often used as pulling and tying elements.

object

Wire classification diagram

1.4.1. Braided steel cable

a. Structure

Steel cables are made from small steel wires with tensile strength up to 1800N/mm 2 and diameter from (0.2 ÷ 1) mm. To manufacture steel cables, people braid the small steel wires into "strands", and from the "strands" they braid into cables. In addition, the steel cable also has a strand made of synthetic or vegetable fibers soaked in lubricating oil to soften the cable.


steel:

Figure 1.17: Steel cable structure

1. Steel wire; 2. Strand; 3. Cable; Steel Cable

The number of steel wires and the number of strands also affect the characteristics of the cable.


• If the cable has many steel wires:

- The cable will be soft (but the durability will not increase significantly because the outer fibers are

large shear stress).

- Poor wear resistance, easily destroyed on impact.

- High manufacturing time cost, high price.

• If the cable has multiple “strands” then:

- Flat cable surface.

- Poor compressive strength.

b. Classification

According to manufacturing method: There are point contact cables, line cables and mixed contact cables.

fit


Figure 1.18: Illustration of point contact and line contact cables. a, Point contact cable; b, Line contact cable

Figure 1.19: Types of line contact cables.

a. The fiber diameters are the same; b. The fiber diameters are the same in each layer.

c. Different fiber diameters in the outer layer; e. Different fiber diameters in the outer layer

d. There is a layer of steel wire as a base between the layers; f. Only the outermost layer has different fibers.

According to the twisted form: There are regular cables and non-twisted cables.

Normal cable is a cable whose fibers and conductors are not deformed. Non-stretch cable is a cable with deformation of fibers and conductors, this cable has the following characteristics:

- Greater abrasion resistance than normal cables.

- Tension is evenly distributed.

- Has better bending resistance, hard

- Reduces wear on drums and pulleys.

According to the twist direction: There are S cables and Z cables

- Right twisted pair cable is also known as Z cable

- Left twisted cable: Also known as S cable

Figure 1.20: Z cable and S cable.

Note: The durability and service life of the cable are influenced by the relationship between the cable twist direction and the rotation direction of the cable drum.



Figure 1.21: Cable twist direction and drum rotation direction

According to braiding method: There are reverse braided cables and same-direction braided cables.

- Reverse braided cable is a type of cable in which the twist direction of the fibers in the strand and the strand in the cable are opposite.

- Same direction braided cable is the type of cable in which the twist direction of the fibers in the strand and the strand in the cable are in the same direction.

Characteristics of reverse braided cable and same-direction braided cable:

+ Reverse braided cable:

- The steel fibers are always under tension, wear increases and durability decreases.

- When not carrying a load, the spiral does not open.

+ Same direction braided cable:

- Flat surface and fuller cross-sectional area.

- Softer, more flexible and durable.

- Less wear due to increased contact surface area.

- Easy to open the twist when not carrying a load.

c. Mode, working conditions and cable calculation method

- Working conditions: Resistant to corrosion, friction and abrasion.

- Working mode: Pulling - Bending - Compressing - Twisting under the effect of tension and rotation speed.

The magnitude of the above stresses depends on many factors:

- Magnitude of applied load,

- Cable structure and diameter,

- The magnitude of friction between the fibers and the strands,

- Size and structure of the drum or pulley.

- The relationship between the twist direction of the cable and the rotation direction of the drum.

The stress state in the cable is complex. In practice, it is impossible to determine the above complicated relationship, so the cable can only be calculated approximately according to the following 3 calculation methods:

Calculation method based on fatigue strength:

Under the simultaneous effect of the above stresses along with continuous bending and straightening during operation, the cable will become tired and eventually destroyed. Therefore, people have come to determine the limit of the number of times the cable can be bent.

The limit value of the number of times the cable can be bent depends on the value of the tension force and the ratio between the diameter of the drum (or pulley) and the diameter of the cable (D 0 = Cd c ). According to SS Torban, the ratio C will be less than 10 for plant cables and C = 15 ÷ 20 for steel cables.

DC Dutscop conducted experiments and showed that with the same load value, if C = 6.8, the cable can withstand about 10.10 3 bends before breaking, when C = 8.6, the limit of the number of bends is 45.10 3 , when C = 10.8, the limit of the number of bends is 100.10 3, when C = 12.9, the limit of the number of bends is 10.10 3 .

3

The limit of bending times is 180.10 and when C = 20.4 then after 600.10 3 bending times the cable will be destroyed.

Thus, if C is increased from 6.8 to 20.4, meaning increased 3 times, the limit of the number of bending times will increase to 60 times with the same load value.

However, the limit number of bends is difficult to calculate accurately due to the influence of many factors that are difficult to determine. Therefore, when selecting cables according to this method, it is mainly based on the dependence graphs between tension and the limit number of bends U gh experimentally.

Calculation method based on tensile and bending strength:

In practice, it is not possible to calculate all tensile, bending, compressive and torsional stresses at the same time, so the cable can only be calculated according to bending and tension, and the torsional and compressive stresses are supplemented by a reserve factor (from experiment).

When the cable is under tension S and bends around a pulley with diameter D, the steel cable has z steel wires, each with diameter d s . The following formula can be used to calculate the selection of steel cable:

Calculation method based on breaking strength:

Nowadays, lifting machines in general, the structures and details of lifting machines in particular have been strongly standardized. Thanks to that, the calculation of steel cables will also be much simpler.

Calculation based on breaking strength is the most commonly used method of cable selection. This method is based on the maximum tension force, reserve strength coefficient and depends on the operating mode of the lifting machine to determine the cable breaking force. From the cable breaking force, we proceed to look up the cable table according to the standard (provided by the steel cable manufacturer) to select the cable.

Step 1 : Calculate S max = S dm k d (Coefficient k d is selected depending on the operating mode of the lift)

Step 2 : Calculate S d = S max n (Safety factor n = 3 ÷ 10)

Step 3 : Look up the cable selection table (See table 6).

Table 6. Soviet steel cable ΛK - 06 x 19 (Γ0CT 3077 – 55)

d. Measures to improve the durability and life of steel cables

- Use the correct load.

- Matching between rotation direction and cable twist direction, between cable diameter and drum or pulley diameter.

- Isolate the environment by covering the surface with a layer of grease.

- Coat the surface of the steel fiber with a layer of anti-corrosion material.

- Regularly grease the cable lug.

e. Connect the cable end to other machine parts

The cable end pair on the shaft needs a cable gland to protect the cable from rubbing directly on the shaft and avoid large crushing stress. The gland has a trough-shaped cross-section (Figure 1.22).

To clamp the cable end, the most commonly used method is a pair of bolts (Figure 1.22). You can also use the braiding method (Figure 1.23): unscrew the cable end, thread the fibers into the cable body, then use steel wire to wrap around the length l. This braiding method is laborious and not very sturdy, so it is rarely used.

Using a conical tube to clamp the cable ends is also very safe (figure 1.24). Thread the cable end through the small hole in the conical tube, cut the middle, bend the wires, retract, and then pour lead into the tube.

Wedge locks (Figure 1.25) are very commonly used and convenient for clamping cable ends. They can be connected and disconnected very quickly by hand without the need for specialized tools.

Figure 1.22

Figure 1.23


Figure 1.24


Figure 1.25

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The above mentioned devices for connecting and pairing cables are standardized.

1.4.2. Welding chain

a. Structural characteristics

Welded chain consists of oval links made from round steel bent and then welded by forging or electric welding. The manufacturing material is usually low-carbon steel with low limit, so the tensile strength and load capacity of the chain are low.

b. Basic dimensions

- Chain diameter d x

- Chain step

- Chain width B

- Chain length L: L = t + 2d

Figure 1.26: Structure of welding chain

c. Classification of welding chains

Based on structure:

- Regular chain.

- Chain with bar.

Based on chain pitch:

- Short chain: t < 3d x

- Long chain: t > 3d x

Based on manufacturing accuracy:

- Chain accuracy: t = ± 0.03d x . and b = ±0.05d x .

- Inaccurate chain: Error of t and B is about ± 0.1d x .

Figure 1.27: Welding chain with crossbar.

d. Characteristics and scope of application

- Easy to bend in all directions (softer than steel cable)

- Simple structure and manufacturing

- Large specific gravity and very sensitive to impacts (noise).

- Susceptible to sudden breakage.

- Chain links are often worn out where they rub.

- Only allows working at slow speed.

- Low tensile strength and low load capacity.

In lifting machines, welded chain is not as widely used as steel wire rope because of its heavy weight and poor reliability.

Usually short link chain is the precision chain used in transmission. Precision chain is used with sprockets with tooth number Z min = 5 with transmission speed not exceeding 0.5 m/s. Non-precision chain is only used with smooth sprockets and drums with transmission speed not exceeding 1 ÷ 5m/s.

Welded chains are suitable for small load lifting mechanisms such as hoists, for transmission in dusty environments where hinge chains cannot be used, or for tying and hanging heavy objects. Welded chains with crossbars are used as anchor chains.

e. Selection method

The chain is mainly subjected to tension, but due to the structure of the chain link, in addition to tension, the chain is also subject to local bending. This stress is difficult to determine, so it is ignored, including the strength of the weld. However, when the chain passes through a drum or pulley, the entire chain link is bent.

Suppose when the chain passes through the pulley, the adjacent links rotate at an angle α. Then the tension force S is divided into two components: (See figure 1.28)

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