wire rope inspection course made in china

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TCK.W products have been accepted by users in China, the United States, the European Union, Japan, South Korea, Singapore and other countries. Users spread over ports, oil, mining, ships, construction, steel and metallurgy, national defense, cranes, elevators, ropeways, and cable-stayed Bridge and many other fields.

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A competent person must begin a visual inspection prior to each shift the equipment is used, which must be completed before or during that shift. The inspection must consist of observation of wire ropes (running and standing) that are likely to be in use during the shift for apparent deficiencies, including those listed in paragraph (a)(2) of this section. Untwisting (opening) of wire rope or booming down is not required as part of this inspection.

Significant distortion of the wire rope structure such as kinking, crushing, unstranding, birdcaging, signs of core failure or steel core protrusion between the outer strands.

In running wire ropes: Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay, where a rope lay is the length along the rope in which one strand makes a complete revolution around the rope.

In rotation resistant ropes: Two randomly distributed broken wires in six rope diameters or four randomly distributed broken wires in 30 rope diameters.

In pendants or standing wire ropes: More than two broken wires in one rope lay located in rope beyond end connections and/or more than one broken wire in a rope lay located at an end connection.

If a deficiency in Category I (see paragraph (a)(2)(i) of this section) is identified, an immediate determination must be made by the competent person as to whether the deficiency constitutes a safety hazard. If the deficiency is determined to constitute a safety hazard, operations involving use of the wire rope in question must be prohibited until:

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If a deficiency in Category II (see paragraph (a)(2)(ii) of this section) is identified, operations involving use of the wire rope in question must be prohibited until:

The employer complies with the wire rope manufacturer"s established criterion for removal from service or a different criterion that the wire rope manufacturer has approved in writing for that specific wire rope (see § 1926.1417),

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If the deficiency (other than power line contact) is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. Repair of wire rope that contacted an energized power line is also prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

Where a wire rope is required to be removed from service under this section, either the equipment (as a whole) or the hoist with that wire rope must be tagged-out, in accordance with § 1926.1417(f)(1), until the wire rope is repaired or replaced.

The inspection must include any deficiencies that the qualified person who conducts the annual inspection determines under paragraph (c)(3)(ii) of this section must be monitored.

Wire ropes on equipment must not be used until an inspection under this paragraph demonstrates that no corrective action under paragraph (a)(4) of this section is required.

At least every 12 months, wire ropes in use on equipment must be inspected by a qualified person in accordance with paragraph (a) of this section (shift inspection).

The inspection must be complete and thorough, covering the surface of the entire length of the wire ropes, with particular attention given to all of the following:

Exception: In the event an inspection under paragraph (c)(2) of this section is not feasible due to existing set-up and configuration of the equipment (such as where an assist crane is needed) or due to site conditions (such as a dense urban setting), such inspections must be conducted as soon as it becomes feasible, but no longer than an additional 6 months for running ropes and, for standing ropes, at the time of disassembly.

If the deficiency is localized, the problem is corrected by severing the wire rope in two; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited. If a rope is shortened under this paragraph, the employer must ensure that the drum will still have two wraps of wire when the load and/or boom is in its lowest position.

If the qualified person determines that, though not presently a safety hazard, the deficiency needs to be monitored, the employer must ensure that the deficiency is checked in the monthly inspections.

All documents produced under this section must be available, during the applicable document retention period, to all persons who conduct inspections under this section.

By definition, wire rope is a twisted bundle of drawn steel wires. It is usually composed of wires, strands, and a core. The wires are drawn to a pre-determined size and laid together in various arrangements having a definite pitch (or lay) to form a strand. The required number of strands are helically laid or formed around the core, which may be a core of synthetic or natural fiber, a metallic strand, or an independent wire rope core.

The size, number, and arrangement of wires, the number of strands, the lay, and the type of core in a rope are determined largely by the service for which the rope is to be used. Flexibility and abrasion are the most important considerations; other factors, such as load conditions, rope speeds, vibration, crushing, and equipment design also must be considered.

Wires are the basic building blocks of a wire rope. They lay around a “center” in a specified pattern in one or more layers to form a strand. The strands are helically laid together around a center, typically some type of core, to form a wire rope.

The strands provide all the tensile strength of a fiber core rope and over 90% of the strength of a typical 6-strand wire rope with an independent wire rope core.

Wire rope consists of multi-strand metal wires wrapped around a suitable core material. Wire-rope cores are carefully designed and must be precisely manufactured to close tolerances to ensure a perfect fit in the rope. The most common types of cores include the following:

2. INDEPENDENT WIRE ROPE CORE( IWRC):Literally an independent wire rope with strands and a core, called IWRC. Most wire ropes made with steel core use an IWRC. The primary function of the core is to provide adequate support for the strands. As the name implies, an IWRC is a separate small-diameter wire rope that is used as the core for a larger wire rope. When severe crushing or flattening of the rope is encountered, an IWRC is usually specified.

3. STRAND COREA strand made of wires. Typically, strand cores are used in utility cables only. This type of core has a single strand used as the core. This type is generally confined to the smaller ropes as a substitute for IWRC. The strand core may or may not have the same cross-section as the surrounding strands.

The first two meanings of “lay” are descriptive of the wire and strand positions in the rope. The third meaning is a length measurement used in manufacturing and inspection.

1. The direction strands lay in the rope – right or left. When you look down a rope, strands of a right lay rope go away from you to the right. Left lay is the opposite. (It doesn’t matter which direction you look.)

2. The relationship between the direction strands lay in the rope and the direction wires lay in the strands. In appearance, wires in regular lay appear to run straight down the length of the rope, and in Lang lay, they appear to angle across the rope. In regular lay, wires are laid in the strand opposite the direction the strands lay in the rope. In Lang lay, the wires are laid the same direction in the strand as the strands lay in the rope.

3. The length along the rope that a strand makes one complete spiral around the rope core. This is a measurement frequently used in wire rope inspection. Standards and regulations require removal when a certain number of broken wires per rope lay are found.

All ropes of the same size, grade, and core in each classification have the same minimum breaking force and weight per foot. Different constructions within each classification differ in working properties. Consider these features whenever you’re selecting a rope for a specific application.

The 6 x 19 classification of wire ropes includes standard 6 strands, round strand ropes with 16 through 26 wires per strand. The 6 x 36 classification of wire ropes includes standard 6 strands, round strand ropes with 27 through 49 wires per strand. Although their operating properties vary, all have the same weight per foot and the same minimum breaking force, size for size.

While the 6 x 19 ropes give primary emphasis to abrasion resistance in varying degrees, the 6 x 36 ropes are important for their fatigue resistance. This fatigue resistance is made possible by the greater number of small wires per strand.

Although there are exceptions for special applications, the constructions in the 6 x 36 classification are primarily designed to be the most efficient for each rope diameter. As the rope size increases, for instance, a large number of wires can be used to achieve the required fatigue resistance, and still those wires will be large enough to offer adequate resistance to abrasion.

The actual diameter of a wire rope is the diameter of a circumscribed circle that will enclose all the strands. It’s the largest cross-sectional measurement as shown here. You should make the measurement carefully with calipers.

The rope diameter should be measured on receipt for conformity with the specification. British Standard (B.S. 302:1987, standard steel wire rope, Part 1. Clause 5.1) allows for a tolerance of - 1% to 4 % of the nominal rope diameter.

The generally accepted method of measuring rope diameter for compliance with the standard is to use a caliper with jaws broad enough to cover not less than two adjacent stands. The measurement must be taken on a straight portion of rope at two points at least 1 meter apart. At each point, two diameters at right angles should be measured. The average of the four measurements is the actual diameter.

After the rope has made the first few cycles under low load, the rope diameter should be measured at several points. The average value of all the measurements at each point must be recorded and will form the basis of comparison for all future measurements.

The measurements of the rope diameter are an essential part of all inspections and examinations. It ensures the maximum diameter reduction does not exceed the recommended figure. As stated in 5.2 British standards 6570 recommends that a wire rope should be discarded when the diameter of the rope is reduced to 90% of the nominal diameter.

A comparison of the measured data with the recorded previous values can detect an abnormal rate of reduction in diameter. Coupled with an assessment of previous rope examination data, the probable date of rope renewal can be predicted.

If we examine the cross-section of a six-stand wire rope, we will find that measuring the thickness of the rope over the crowns (Fig-a) will produce a higher value than measuring it over the valleys (Fig-b). The actual diameter of the rope is defined as the diameter of the circumscribing circle.

PREPARATION FOR INSTALLATION Most ropes is shipped with the ends seized as they are prepared for cutting. You can usually install seized ropes without further preparation. In some cases, though, tight openings in drums and wedge sockets – or even complicated reeving systems – require special end preparation. Then, the strands must be tightly held without increasing the rope diameter. In such cases, the ends are tapered and welded, or the ends fused. It’s sometimes necessary to provide a loop or link to which a lighter line is fastened to pull the rope into place or around sheaves.

Some of these special end preparations are shown here. With the exception of category 1 rotation-resistant ropes, any end preparation that results in welding or fusing of the rope must be cut off in a manner that leaves the strands and wires free to adjust before you clamp or seat it in an end termination. Welded ends must remain on category 1 rotation resistant ropes and XLT4. If a situation arises in the field that requires the cutting of a category 1 rotation-resistant rope, we have special preparation and cutting instructions available.

A hoist wire rope is a machine in and of itself that requires proper selection, installation, and maintenance. As a wire rope is used in a hoisting application, the individual wires move and allow the rope to bend around the drum and sheaves. This movement causes friction and abrasive forces that require proper lubrication. If selection, installation, operation, or maintenance is improper, the rope life will be shortened dramatically. Even under the optimum conditions and usage, every wire rope used in a hoisting application will eventually fail. Therefore, routine periodic inspections, by a trained and qualified inspector must be employed to determine the condition of the wire rope so that replacement is made before the rope fails.

Click the below link to know more in detail about Wire ropes classes, damages, and inspection guidelines, PowerPoint presentation on wire rope examination, classification, damages, and a wire rope sling safety guidelines, etc. in one page.

(3) Operational aids. Operations must not begin unless operational aids are in proper working order, except where the owner or lessee meets the specified temporary alternative measures. See WAC 296-155-53412 for the list of operational aids.Note:All accredited crane certifiers must meet and follow the requirements relating to fall protection, located in chapter 296-880 WAC, Unified safety standards for fall protection.

(a) Wire ropes must meet the crane or wire rope manufacturer"s specifications for size, type and inspection requirements. In the absence of the manufacturer"s specifications, follow the requirements for removal criteria located in this section, including Table 1.

Derricks63Consult rope mfg.Consult rope mfg.32*Also remove if you detect 1 wire broken at the contact point with the core or adjacent strand; so called valley breaks or evidence from any heat damage from any cause.Note:xd means times the "diameter."

(b) The accredited crane certifier must perform a complete and thorough inspection covering the surface of the working range plus 3 additional wraps on the drum of the wire ropes.

(ii) If the deficiency is localized, the problem is corrected by severing the wire rope; the undamaged portion may continue to be used. Joining lengths of wire rope by splicing is prohibited.

(e) Replacement rope must be of a compatible size and have a strength rating at least as great as the original rope furnished or recommended by the crane manufacturer.

(a) Sheave grooves must be free from surface defects that could damage the rope. The cross-sectional radius at the bottom of the groove should be such as to form a close fitting saddle for the size of rope used. The sides of the groove must be tapered outward and rounded at the rim to facilitate entrance of the rope into the groove. Flange rims must run true about the axis of rotation.

(a) A safe test area must be selected and all traffic and unauthorized personnel and equipment must be cleared from test area. This test area must be roped off or otherwise secured to prevent entry of unauthorized personnel and equipment;

Wire ropes undergo constant stress and wear through daily use. So, wire rope requires monthly inspection in accordance with this section to reduce the risk of failure and potential resulting injury or property damage. In addition, this section covers criteria to use in determining when to replace rope, and requires inspection of rope on equipment that has been idle for a month or more, before the rope and equipment can be returned to service.

A thorough inspection of all ropes shall be made at least once a month and a certification record which included the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:

All rope which has been idle for a period of a month or more due to shutdown or storage of a crane on which it is installed shall be given a thorough inspection before it is used. This inspection shall be for all types of deterioration and shall be performed by an appointed person whose approval shall be required for further use of the rope. A certification record shall be available for inspection which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the rope which was inspected.

Wear and damage to wire rope can’t always be seen on the surface. Konecranes RopeQ Magnetic Rope Inspection pairs visual inspection with non-destructive testing to detect internal broken wires that may escape detection through traditional inspection methods.

A Chinese finger provides a quick and fast means of (temporary) terminating different kinds of steel wire rope. The grips can be used for reeving and pulling of steel wire rope onto blocks or cranes. They are made from woven mesh galvanized steel wires leading to a very flexible and easy to handle termination

Tianjin Goldsun Wire Rope Limited (the〝Goldsun〞) is a specialist manufacturer of elevator ropes that is venture between by Hong Kong Publicly Listed Company, Golik Holdings Limited and Tianjin Metallurgy Group Co., Limited, a Top 500 manufacturing enterprise in China. The company pioneered the development and manufacture of wire ropes in China and today distinguishes itself as the market leader in the industry in the manufacture and supply of wire rope products and OEM elevator ropes.

Formed in January 2002, Goldsun perpetuates the beliefs of the importance of quality management, innovation, technical and quality excellence, product leadership, and people development in our pursuit to grow and reach out to more customers. In 2010, Goldsun’s “Three Stage” development strategy guided the investment to build a new RMB150 million state-of-the-art manufacturing facility that is capable of 40,000 tonnes annual output of high-quality and specialized wire ropes. Production began in April 2011 and has enabled the company to deliver better products to our customers at an even higher level of customer experience and satisfaction. Along with an in-house research and development (R&D) unit, the facility at present is equipped with advanced SKET pre-stretch closers, double twist bunchers, sisal core machines, in addition to well over 300 sets of leading domestic surface cleaning, wire drawing, heat treatment, stranding, closing and fatigue testing equipment to place Goldsun as one of the world’s largest integrated single product manufacturer and supplier of its category.

The future and long-term orientation culture ofGoldsun to invest in R&D, technology and in developing the competence of our people in various capacities and across specialist disciplines had allowed us to produce the widest range of elevator ropes in the world that meets customer requirements and complies with OTIS, Japanese and International standards.

In addition to being ISO9001:2000 and Otis Q-Plus certified, Goldsun had also achieved the Korean KTL Production Certification and was first in China to pass fatigue tests conducted at Otis HQ’s Farmington Engineering Test Centre. In 2004,Goldsun supplied the special high speed elevator ropes for the Guinness World Record Zhangjiajie Bailong Elevator which remains in active use today and is highly commended. Furthermore, multiple accolades in product quality excellence was earned numerous times including the National Golden Cup Award, the prestigious designation as the nation’s Top 10 enterprise brand satisfaction survey in 2006, and for five consecutive times over a period of fifteen year, laurels in product and after-sale service excellence by the China Quality Association Users Committee and National Construction Machinery Equipment Users Committee.

At the heart of Goldsun’s world-class capabilities in R&D, design and manufacture are bespoke services and solutions for our customers starting from application selection through to installation and maintenance. Our wide selection of products and our network of service centers in Guangzhou, Shanghai, Chongqing, Suzhou and Chengdu give us the ability to offer customers timely services in cut-to-length orders, packaging and distribution; and make Goldsun the top supplier of elevator ropes in China for many years running. Goldsun is also the qualified supplier for companies like OTIS, Hitachi, Toshiba, Yongtay, Tissen, and etcetera.

Wire Rope Rigging Inspection & ReplacementThis micro-learning module covers the basics of wire rope inspections and how to know when a wire rope needs replacing.

This micro-learning module covers the basics of wire rope inspections and how to know when a wire rope needs replacing. Great for refreshers or toolbox talks/tailgate meetings!

Wire ropes are widely used in industrial production, tourist cable cars, bridges, metallurgy, mining, and informal elevators. Therefore, it is important to ensure the safety of the wire ropes being used. The study of the residual strength of wire ropes is significant for developing advanced instruments that can quantitatively detect wire-rope defects [1]. Currently, the stable and safe working performance of wire ropes is of interest to more and more scholars who are interested in checking the remaining longevity of wire ropes by using online inspection devices.

Jomdecha [2] improved on equipment that was magnetized by electric current. The equipment was designed to control the strength of magnetization by adjusting the magnetized power supply or engaged loops. One special type of testing coil was designed to capture the MFL signals. An eddy current testing method [3] that used an alternating current to generate eddy current in the wire rope was proposed. A function model, which explained the relationship among defects, characteristic vectors, sensor parameters and wire ropes was established by relying on the testing data features. Raišutis [4] studied the dispersion curves of ultrasonic guided-wave spread inside wire ropes. On the basis of this research, the best and most promising receiving positions for ultrasonic guided-waves were calculated. In [5] Peng and Wang designed a visual system on the basis of gamma rays. This system focused on thick ropes used in a suspension bridge. Li et al. [6], used X-ray to detect defects in the steel core of transmission belts. They also proposed a modified threshold rules method, which captured the approximate shape of defects in the steel core.

For the detection of wire rope gaps, Wang and Tian [7] applied the analysis method of finite element to the MFL of wire ropes, and proposed an excitation method that adopted magnetic cores into a magnetic column to improve the magnetic leakage strength of gaps. A system of strong magnetic detection was designed using Hall sensors. During detection of the magnetic leakage signals of wire ropes, the air gap affected the testing accuracy, therefore, Wang et al. [8] studied the influence of different lift-off distances and different air gaps on detection accuracy and improved the structural designs of the detector and the exciter. This device inhibited the influence of lift-off variation. Li et al. [9] investigated the excitation model, established a design standard for the magnetizing structure whose theoretical size was solved through numerical solution, and used finite-element analysis to verify the theoretical size so that the final size was adjusted and determined. Some researchers adopt digital-image processing (DIP) for the MFL signals, Cao et al. [10] unrolled the MFL signals to grayscale, applied the DIP to extract the characteristics of the grayscale image, and identified the different defects. Zhang et al. [11] discussed the limits of lift-off with the digital signal processing method and designed a digital band trap to inhibit the strand waves of wire ropes. The sizes of different defects, which were processed and recognized with statistics, were described as binary images. Furthermore, Zhang et al. [12] designed a spatial filter to inhibit the strand texture of defects of grayscale image and extracted textural features of filtered defects. Finally, a BP neural network was designed and used for the quantitative identification of defects. Recently, most nondestructive testing (NDT) devices were designed using a permanent magnet as an excitation component, which excited wire rope to saturation magnetization. The MFL signals were captured by Hall sensors [10,11,12,13].

The most important aspect of a quantitative detection system is noise filtering of MFL signals. To some degree, the selected filtering algorithm would have a major effect on the quantitative inspection results. Taking into account the previously mentioned algorithm, Cao et al. [14] discussed the relationship between the temporal domain and spatial domain of electromagnetic testing signals of wire ropes, proposing a sampling theorem of the space-time signals, and the collection and processing of the space-time signals was described in detail. Tian et al. [15] combined wavelet transform (WT) and morphological transformation, and presented a morphological filtering algorithm used to inhibit the baseline drift of MFL signals. For the quantitative inspection method, Zhang and Xu [16] discussed the wavelet neural network model and weight-learning algorithm.

In this paper, GMR sensors were distributed uniformly on the circumference of the wire rope to capture the three-dimensional radial direction MFL signal of wire ropes’ residual magnetism. Compressed sensing (CS) and wavelet filtering algorithms were used to eliminate noise signals. The defect signal was translated into a two-dimensional image. For the image, the features that served as inputs for damage inspection were extracted. Experimental results show that this method can better distinguish the amount and width of broken wires and depict circumferential distribution of the defects. The device has the advantages of high detection speed, high precision, structural simplicity, as well as being lightweight, small in size, and low cost.

The paper is organized as follows: the remanence detection head device, data acquisition board and MFL imaging approach are introduced in Section 2. Section 3 focuses on noise elimination, which includes reprocessing the MFL signal and using the CSWF algorithm. The filtered MFL signal was grayed into an image that was interpolated circumferentially. Next, positioning detects and dividing negative axle waveform of defects, extracting morphological eigenvalues and invariant moments as identification vector. Section 4 presents a BP neutral network design that uses the extracted vector as inputs. Finally, the quantitative inspection of broken wires was completed. Section 5 includes comments and the discussion of this paper. Section 6 concludes the paper indicating major achievements and future scope of this work.