wire rope connectors and tensioners free sample

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Each use for a custom wire rope cable assembly has its own unique purpose.  We can assist you in designing a custom cable assembly to fit your specific needs.

Factors to Consider When Designing A Cable AssemblyWhen it comes to cable assembly design, a number of factors need to be considered such as work load, abrasion, cycle life, and flexibility, environment, cost and safety.

Tyler Madison, Inc. specializes in cable size from 3/64" - 3/8" in diameter and 270 lbs. - 14,400 lbs. in breaking strength.  We will put our years of experience to work in helping you design and produce exactly what you need.  We have manufactured quality custom wire rope cable assemblies for leading companies in the following industries:Aerospace

Tyler Madison is an industry leading manufacturer of wire rope cable assemblies and custom wire and cable. Our knowledge and experience give us the capability to manufacture standard and custom wire rope assemblies and products for a variety of industrial clients. With in-house engineering and design services, you can get the exact kinds of wire rope assemblies and steel wire cable products that you are looking for from one place at an affordable price. Call us today to find out what types of cable assemblies we can do for you!

Lexco® Cable offers a large selection of wire rope and aircraft cable hardware and tools. Our hardware items are made for attaching cable and wire rope to structures, supports, and other cables and wire ropes. Unlike our cable fittings, this hardware is not crimped or swaged to the wire rope or cable but is attached through other means, generally through an eyehole on the hardware itself. Our tools are designed to make working with and attaching aircraft cable, wire rope, and hardware faster, easier, and safer.

All of our aircraft cable and wire rope hardware is available in bulk quantities or as part of a complete cable assembly. We specialize in cable assembly fabrication to save you time and money in additional production costs.

Request a quote for the aircraft cable or wire rope hardware items or tools you need, or contact Lexco® for more information. If you cannot find the hardware items or tools that you need in our online inventory, please contact your Lexco® Cable sales representative. We’ll be happy to help you find the ideal product for your application.

Galvanized steel ropes in 11 different thicknesses: 1mm, 1.5mm, 2mm, 3mm, 4mm, 6mm, 8mm, 10mm, 12mm, 14mm and 16mm.Equipped with eyelets, hims, as winches, or forestry rope and set for tensioning.The steel ropes are processed in Germany after the DIN-European standard 13414.

Wire rope meter in 11 different thicknesses: 1mm, 1.5mm, 2mm, 3mm, 4mm, 6mm, 8mm, 10mm, 12mm, 14mm and 16mm.Smoothed in five different constructions: 7x7, 6x19, 7x19, 6x37 and 18x7 Available as a rotary wire rope.All offered wire ropes correspond to the DIN EN 13414-1.

galvanized wire ropes with eyelets in the strengths of 1mm to 16mm according to the specifications of the DIN-European standard 13414-2 made in Germany and optimally suitable for many applications.

Our steel cables with box galvanized steel, high quality and strict DIN specifications pressed in 2mm - 16mm strength.The cheese according to DIN6899 protects the wire rope from the inside to the load absorption point.

galvanized steel ropes tension with the help of firmly connected steel cable clamps or in set with clamps, tensionersand sleep.You will receive the sets both with smoothly cut steel rope as well as with a one-sided shew of the compression.

wire rope with hook in different versions: for light suspensions with snap hooks, as choker rope with high-strength sliding hookFor forstarts, steel cable with hooks and eyelets or as a wire rope for winches.The steel ropes are processed in Germany after the DIN-European standard 13414 and are pressed with carabiner hooks, load hooks or eyelethook of Grade 8.

Our steel cables with rope stopper " are compressed from galvanized steel in 1.5mm - 12mm strength and can be opened with an open end,to be ordered a loop or kausche.The one-sided pressed round clamp according to DIN 13411-3 fulfills the purpose of a stop terminal.

forestry ropes in seven different strengths of 5mm - 16mm.Available as choker rope with high-strength sliding hook, stop rope with hook & loop, as well as with grade 8 Load hook.The steel cables are processed in Germany after the DIN-European standard 13414 and are not highly damaged.

wire ropes for winches in eight different strengths: 4mm, 5mm, 6mm, 8mm, 10mm, 12mm, 14mm and 16mm.The wire ropes are made up to a thickness of 8mm annealed, so that fixing in the wind is very easy and easy to use.

Our Rotary wire ropes Get with the construction 18x7 in 5 different strengths. Through the,In opposite directed, strand layers, the wire ropes exert a low torque to an isolated load.The wire rope optimally serves as Hub - or Kranil to lift and depend on appropriate loads.

Labels With a compressed cheese according to DIN 6899 and a glow-separated end in 13 different lengths of 0.5m - 20m, optionally equipped with a wire cable holder and in the strengths of1.5mm - 8mm permanent & fast available.

Wire ropes for garage doors With a compressed cheese to DIN 6899 and a glow-separated end in individual length, optionally pressed with a M10x100 eye screw and in the strengths of 2mm- 5mm permanent & fast available.

Our steel rope sets are equipped with a steel cable and matching clamps, himming and wire ropes.You can choose from both different lengths, different strengths, as well as different equipment.

Our Fuse ropes for the event technique correspond to the BGV-C1 guidelines (security for events and production loads over persons) and can be optimal forLoads of 2kg - 100kg be used.

Our horizontal Rope locking system " SAVEKINGLINE?® corresponds to the DIN EN 795 type C? and serves as fall protection of personsFor the use on high-volume workplaces.The cable locking system is available in variable or defined length.

wire rope for a shoot for three different web lengths: 25m, 50m and 100m.The tension rope is one-sided melted and pressed on one side with a cheaper and equipped with a emergency element.

Wire rope and cable are each considered a “machine”. The configuration and method of manufacture combined with the proper selection of material when designed for a specific purpose enables a wire rope or cable to transmit forces, motion and energy in some predetermined manner and to some desired end.

Two or more wires concentrically laid around a center wire is called a strand. It may consist of one or more layers. Typically, the number of wires in a strand is 7, 19 or 37. A group of strands laid around a core would be called a cable or wire rope. In terms of product designation, 7 strands with 19 wires in each strand would be a 7×19 cable: 7 strands with 7 wires in each strand would be a 7×7 cable.

Materials Different applications for wire rope present varying demands for strength, abrasion and corrosion resistance. In order to meet these requirements, wire rope is produced in a number of different materials.

Stainless Steel This is used where corrosion is a prime factor and the cost increase warrants its use. The 18% chromium, 8% nickel alloy known as type 302 is the most common grade accepted due to both corrosion resistance and high strength. Other types frequently used in wire rope are 304, 305, 316 and 321, each having its specific advantage over the other. Type 305 is used where non-magnetic properties are required, however, there is a slight loss of strength.

Galvanized Carbon Steel This is used where strength is a prime factor and corrosion resistance is not great enough to require the use of stainless steel. The lower cost is usually a consideration in the selection of galvanized carbon steel. Wires used in these wire ropes are individually coated with a layer of zinc which offers a good measure of protection from corrosive elements.

Cable Construction The greater the number of wires in a strand or cable of a given diameter, the more flexibility it has. A 1×7 or a 1×19 strand, having 7 and 19 wires respectively, is used principally as a fixed member, as a straight linkage, or where flexing is minimal.

Cables designed with 3×7, 7×7 and 7×19 construction provide for increasing degrees of flexibility but decreased abrasion resistance. These designs would be incorporated where continuous flexing is a requirement.

Selecting Wire Rope When selecting a wire rope to give the best service, there are four requirements which should be given consideration. A proper choice is made by correctly estimating the relative importance of these requirements and selecting a rope which has the qualities best suited to withstand the effects of continued use. The rope should possess:Strength sufficient to take care of the maximum load that may be applied, with a proper safety factor.

Strength Wire rope in service is subjected to several kinds of stresses. The stresses most frequently encountered are direct tension, stress due to acceleration, stress due to sudden or shock loads, stress due to bending, and stress resulting from several forces acting at one time. For the most part, these stresses can be converted into terms of simple tension, and a rope of approximately the correct strength can be chosen. As the strength of a wire rope is determined by its, size, grade and construction, these three factors should be considered.

Safety Factors The safety factor is the ratio of the strength of the rope to the working load. A wire rope with a strength of 10,000 pounds and a total working load of 2,000 pounds would be operating with a safety factor of five.

It is not possible to set safety factors for the various types of wire rope using equipment, as this factor can vary with conditions on individual units of equipment.

The proper safety factor depends not only on the loads applied, but also on the speed of operation, shock load applied, the type of fittings used for securing the rope ends, the acceleration and deceleration, the length of rope, the number, size and location of sheaves and drums, the factors causing abrasion and corrosion and the facilities for inspection.

Fatigue Fatigue failure of the wires in a wire rope is the result of the propagation of small cracks under repeated applications of bending loads. It occurs when ropes operate over comparatively small sheaves or drums. The repeated bending of the individual wires, as the rope bends when passing over the sheaves or drums, and the straightening of the individual wires, as the rope leaves the sheaves or drums, causing fatigue. The effect of fatigue on wires is illustrated by bending a wire repeatedly back and forth until it breaks.

The best means of preventing early fatigue of wire ropes is to use sheaves and drums of adequate size. To increase the resistance to fatigue, a rope of more flexible construction should be used, as increased flexibility is secured through the use of smaller wires.

Abrasive Wear The ability of a wire rope to withstand abrasion is determined by the size, the carbon and manganese content, the heat treatment of the outer wires and the construction of the rope. The larger outer wires of the less flexible constructions are better able to withstand abrasion than the finer outer wires of the more flexible ropes. The higher carbon and manganese content and the heat treatment used in producing wire for the stronger ropes, make the higher grade ropes better able to withstand abrasive wear than the lower grade ropes.

Effects of Bending All wire ropes, except stationary ropes used as guys or supports, are subjected to bending around sheaves or drums. The service obtained from wire ropes is, to a large extent, dependent upon the proper choice and location of the sheaves and drums about which it operates.

A wire rope may be considered a machine in which the individual elements (wires and strands) slide upon each other when the rope is bent. Therefore, as a prerequisite to the satisfactory operation of wire rope over sheaves and drums, the rope must be properly lubricated.

Loss of strength due to bending is caused by the inability of the individual strands and wires to adjust themselves to their changed position when the rope is bent. Tests made by the National Institute of Standards and Technology show that the rope strength decreases in a marked degree as the sheave diameter grows smaller with respect to the diameter of the rope. The loss of strength due to bending wire ropes over the sheaves found in common use will not exceed 6% and will usually be about 4%.

The bending of a wire rope is accompanied by readjustment in the positions of the strands and wires and results in actual bending of the wires. Repetitive flexing of the wires develops bending loads which, even though well within the elastic limit of the wires, set up points of stress concentration.

The fatigue effect of bending appears in the form of small cracks in the wires at these over-stressed foci. These cracks propagate under repeated stress cycles, until the remaining sound metal is inadequate to withstand the bending load. This results in broken wires showing no apparent contraction of cross section.

Experience has established the fact that from the service view-point, a very definite relationship exists between the size of the individual outer wires of a wire rope and the size of the sheave or drum about which it operates. Sheaves and drums smaller than 200 times the diameter of the outer wires will cause permanent set in a heavily loaded rope. Good practice requires the use of sheaves and drums with diameters 800 times the diameter of the outer wires in the rope for heavily loaded fast-moving ropes.

It is impossible to give a definite minimum size of sheave or drum about which a wire rope will operate with satisfactory results, because of the other factors affecting the useful life of the rope. If the loads are light or the speed slow, smaller sheaves and drums can be used without causing early fatigue of the wires than if the loads are heavy or the speed is fast. Reverse bends, where a rope is bent in one direction and then in the opposite direction, cause excessive fatigue and should be avoided whenever possible. When a reverse bend is necessary larger sheaves are required than would be the case if the rope were bent in one direction only.

Stretch of Wire Rope The stretch of a wire rope under load is the result of two components: the structural stretch and the elastic stretch. Structural stretch of wire rope is caused by the lengthening of the rope lay, compression of the core and adjustment of the wires and strands to the load placed upon the wire rope. The elastic stretch is caused by elongation of the wires.

The structural stretch varies with the size of core, the lengths of lays and the construction of the rope. This stretch also varies with the loads imposed and the amount of bending to which the rope is subjected. For estimating this stretch the value of one-half percent, or .005 times the length of the rope under load, gives an approximate figure. If loads are light, one-quarter percent or .0025 times the rope length may be used. With heavy loads, this stretch may approach one percent, or .01 times the rope length.

The elastic stretch of a wire rope is directly proportional to the load and the length of rope under load, and inversely proportional to the metallic area and modulus of elasticity. This applies only to loads that do not exceed the elastic limit of a wire rope. The elastic limit of stainless steel wire rope is approximately 60% of its breaking strength and for galvanized ropes it is approximately 50%.

Preformed Wire Ropes Preformed ropes differ from the standard, or non-preformed ropes, in that the individual wires in the strands and the strands in the rope are preformed, or pre-shaped to their proper shape before they are assembled in the finished rope.

This, in turn, results in preformed wire ropes having the following characteristics:They can be cut without the seizings necessary to retain the rope structure of non-preformed ropes.

They are substantially free from liveliness and twisting tendencies. This makes installation and handling easier, and lessens the likelihood of damage to the rope from kinking or fouling. Preforming permits the more general use of Lang lay and wire core constructions.

Removal of internal stresses increase resistance to fatigue from bending. This results in increased service where ability to withstand bending is the important requirement. It also permits the use of ropes with larger outer wires, when increased wear resistance is desired.

Outer wires will wear thinner before breaking, and broken wire ends will not protrude from the rope to injure worker’s hands, to nick and distort adjacent wires, or to wear sheaves and drums. Because of the fact that broken wire ends do not porcupine, they are not as noticeable as they are in non-preformed ropes. This necessitates the use of greater care when inspecting worn preformed ropes, to determine their true condition.

Of course ,we have to know your application firstly and a number of factors have to be considered, such as work load, safety abrasion, environment ,cycle life, flexibility, cost, When we design the stainless steel wire.

Yes. We are a professional manufacturer of wire assemblies with 15 years producing experience in China .We have always been cooperating with domestic and overseas customers and partners with the first- class quality and service to make great achievements. If this is your first time to contact us, please trust us, we’ll not let you down.

Early tower installations for radio broadcasting offered problems similar to those met in guying stacks, poles, derricks and similar structures. Guys for these moderate-height structures were commonly made of regular wire rope.

The advent of television and FM broadcasting, however, created a need for towers of greater height. In fact, the idea of a tower being 2,000 feet tall or more is no longer uncommon. The guying of these larger towers presented problems not faced with the smaller towers. For example, wind and ice loads must now be considered, both during installation and tensioning after erection.

Structural strand is now used for guy systems. Where larger diameter wire rope was once used, structural strand, with its higher modulus of elasticity and lower diameter-to-strength ratio, allows for smaller diameter guys. This reduction in diameter reduces ice and wind loads, which may be important in the overall design of the tower. Structural strand’s higher modulus of elasticity (less stretch) also allows for less take-up of the bolts during tensioning.

Uniformity in tensioning and deflection is necessary for tower guys. Therefore, it is important that the structural strand guys have minimal constructional stretch, a high modulus of elasticity and accurate length measurements. Pre-stretching the strand eliminates most of the constructional stretch and contributes to the strand’s high modulus of elasticity. Proof loading may be used to prove the security of end attachments. Field tensioning of the guys is facilitated by our ability to supply precisely measured and completely documented strand assemblies.

Suspension systems are ideal where long spans are required, as in highway and pedestrian bridges, supporting conveyors, pipe lines and overhead passageways in industrial plants, and overhead crossovers above railroads.

When appearance, durability, utility and ease of construction are considered, suspension bridges are often the most economical to build. For example, flood damage to exposed piers is eliminated and difficult or dangerous pier foundations can be avoidedwith a suspension-cable construction. Often the entire problem area is spanned; the foundations can be located at economical installation points where they are least likely to be damaged. Great clearance is obtained since the supporting structure is above the floor and has no intermediate supports.

Stiffening trusses may be incorporated into the design of foot bridges and similar bridges, where they also may serve as hand railings. These trusses add relatively little to the cost of the structure, and they ensure a bridge free from disturbing floor movement.

Structural strand and wire rope is used for the main cables, suspenders and wind cables of highway, pedestrian and pipeline suspension bridges. Structural strand is manufactured through 5 1/2” diameter and wire rope up to 7” diameter.

Pre-stretching greatly reduces the constructional stretch ofthe structural strand or wire rope and improves the overall elastic stability. While in the pre-stretcher, overall lengths and intermediate tower and suspender points can be measured to close tolerances under prescribed tensions.

In a tied arch bridge, the bridge deck is suspended by structural strand or wire rope hangers hung from a steel or concrete arch. Tied arch bridges normally cross short to medium spans. Structural strand has been used in tied arch bridges having span lengths of more than 1,000 feet.

The cable stayed bridge is a relatively new type of bridge, in which structural cables radiate diagonally from one or more towers or pylons to a connection point on the bridge girder. This bridge form allows a very efficient use of material, which results in a lighter structure and less massive foundation.

Galvanized helical structural strand has been specified for cable stays as have several other cable configurations. Various types of socket attachment and corrosion protection systems have been used with varying degrees of success. Zinc-poured attachment of sockets is recommended. Corrosion protection systems are too varied and rapidly evolving to recommend a particular system.

Each corner of the span is connected to the counterweights by sets of large wire ropes which operate over parallel-grooved sheaves at the top of the towers. Using powered winch drums, smaller wire ropes raise and lower the movable span.

The lengths of the counterweight ropes in each of the four corners must be matched closely to ensure equalization of tension. Uniform stretch also is an important factor. In vertical lift bridges where counterweight clearances are limited, ropes should have minimal constructional stretch. Counterweight ropes can be pre-stretched to reduce constructional stretch, and measured under tension to ensure closer control of rope lengths. Normally, operating ropes do not require pre-stretching since minor length adjustments can be made at the drums.

In recent years, design and construction of structures with cable-supported and cable-suspended roofs has increased. As opposed to other methods, cable roof structures permit economical, column-free construction over large spans. Cable roofs also decrease the stresses on the superstructure, supporting members and the foundation, thereby permitting the use of fewer and lighter materials. Cable roofs offer a bold challenge to architects and structural engineers who seek new ways to utilize interesting techniques and materials.

A cable-suspended roof uses cables to directly carry the roof load. There are two variations of this principle: (1) cases where the roof deck is carried directly on the cable; and (2) cases where additional loads, such as ceiling frames, are suspended directly from and below the cable.

The most elementary structural suspension system is a catenary, which is similar to that of a suspension bridge. This system usually requires end towers and abutments to resist the tension in the catenary and a stiffening structure to eliminate the flutter in the roof system.

To avoid flutter without adding heavy weight, grids of interlacing cables are sometimes used to dampen the catenary assemblies. In some cases,these surfaces contain reverse curves (convex) created by cables having opposite curvatures; usually, these convex cables have an initial tension and mirror the concave catenary cables.

When flutter problem has been solved by placing a mass on top of the cables, such as precast concrete planks, this additional mass adds to the superimposed weight. Damped cables, on the other hand, do not require additional weight to avoid flutter.

A properly damped, suspension system, consisting of cables designed to resist all superimposed static loads, may be covered with a light roofing material.

A number of such suspension roofs and systems have been built, and they have demonstrated a complete absence of flutter and a high degree of rigidity. Though much lighter in weight, their rigidity is comparable to, or higher than, conventional structural elements of steel trusses or girders.

Related to grid roofs with reverse curvature are tensioned fabric roofs. In this case, a roofing fabric may be attached to the roof cables before tensioning. As the cables are tensioned, the fabric takes on tension as well. As a result, the tensioned fabric roof is very light and rigid, and can usually be quite attractive.

One specific type of tensioned fabric roof is the “Tensegrity” dome. Roofs of this type have been built spanning over 700 feet of column-free space. Cables are used as concentric tension hoops, tied together by upper and lower chord and diagonal cables. Vertical posts in compression keep the cable system in tension, resulting in a series of cable trusses. When tied together, these cables provide a tensioned roof structure over which the roofing fabric is stretched. The result is a very light roof, admitting natural light and allowing maximum unobstructed views inside the structure.

Covering both large and small spans, air-supported roofs resemble balloons in both appearance and function. Fabric and cable may form both walls and roof in small temporary buildings. When connected to a wall structure, as in a sports stadium, air-supported roofs provide a light, long-span roof system which allows natural light and long unobstructed sight distances within the building. When the roof is inflated, the cable network restrains the fabric from excessive stretch and also provides structural support for lighting, sound and HVAC systems, service walkways and visual effects such as scoreboards and video monitors. In case of deflation in a stadium, the cables, although in a relaxed position (a catenary), still support all the apparatus, as well as the fabric.

You may have the perfect electric fence tape (or wire, or rope), the sturdiest electric fencing posts, the safest insulators, the most accurate electric fence tester, a great fault finder and a backup meter or indicator to boot, but unless you invest in the reliable joints that keep your fence in one continuous electric system, that powerful voltage isn’t going anywhere.

Those “joints” - the connectors, joiners, and tensioners of your fence system - act as links of continuity that keep your electricity flowing and your fence line stretched tense. The best energisers in town can’t guarantee that the current they generate will make it through the end of an electric system, but that’s where the little connectors and tensioners deliver their promise!

Now you may ask: to make sure you’re the most “well-connected” person around, where can you find the best quality equipment for the lowest price? If you’re in the mainland UK, consider skipping a long drive to the hardware shop and buy from us online.

Connectors, joiners and tensioners constitute the backbone of your electric fencing system; without a way to link your ropes, wire or tape, there would be no continuity in your electric fence and therefore no way to keep your four-legged friends in their proper pastures.

Since these joints in the fencing are so integral to your electric system, how do you go about choosing and using quality equipment? With connectors, joiners and tensioners, your first step is easy: all of these accessories are made according to what type of material you’re using for your fence, so you will initially narrow down your options based on whether ropes, tape, or wires are your conductor of choice.

Once that choice is made, you’ll want to consider what style of each accessory will suit your needs or preferences. For example, certain types of tensioners are great for end of line use, while others can sit anywhere on the line. Specific connectors are used for line to line connection, while others are intended for joining one end of the rope to another for continuity purposes.

Do you have two or three lines of rope, wire or tape that you would love to connect with each other, thereby ensuring that your current stays current along your fence line? Allow connectors to do the work: these nifty pieces of equipment act as vertical allies to your horizontal fence lines.

The parallel nature of your fence lines means that your individual lines, working so hard to keep those critters in line, never intersect each other. By transferring electric energy between them, connectors allow your lines to work in tandem in teams of two or three. Our tape to tape, wire to wire and rope to rope connectors all do the job as emissaries between energy lines.

Joiners are similar to connectors - the only difference is that they don’t include devices that connect line to line. If you’re the proud owner of an electric tape fence, tape connection buckles act as simple joiners that conduct electricity between the ends of two tape lines.

Our electric rope joiners promise that the quality of current streaming through your rope remains unbroken, and they’re so straightforward that you simply require a screwdriver to set them up.

Alternatively, if you value the small things in life and your fence happens to be made of galvanised wire, consider a bolt joiner. They’re tiny, but these heavy-duty nuggets will keep your fence secure and unbroken. Whatever material you use, joiners are a go-to accessory that creates an essential support system for your fence.

Tensioners are used to - you guessed it - ensure that your fence material remains taut so that no wayward animals become entangled in wire or decide a low-hanging rope is a jump. There are two main types: ratchet tensioners and in-line tensioners.

Ratchet tensioners are ideal for end of line installation, as the toothed wheel permits them to spool up loose galvanised wire in one direction so that your fence stays taut as a tightrope. In-line tensioners are great for installation along the fence line and can be made of varying materials - nylon and aluminium being the most popular.

Our variety of in-line tensioners accommodate poly wire, tape and rope and come in packs of at least four, giving you the opportunity to both save and have some spares on hand.