steel wire rope images made in china

6×19 construction wire rope is available with either FC (fibre core) or WSC (wire strand core). When supplied with a wsc the rope is more commonly referred to as 7×19. The rope is very popular in diameters from 3mm to 16mm and is used on a variety of applications. 6×19 FC and 6×19 WSC (7×19) is very flexible in diameters 3mm to 6mm and is used for many requirements where wire ropes are running over pulleys. 7×19 construction is readily available in both galvanised and marine grade stainless steel.

Steel wire rope for all types of cranes including Tower Crane, Container Crane, Mobile port Crane, Offshore Crane, Loading Crane, Pilling Crane, Overhead cranes and more.

Shenwei can package the rope by plywood reels(500M-2000M), soft coils(10M-200M), plastic reels(100-300M) and other packages according to customer’s requirement.

Regarding the stainless steel wire rope, the material is AISI304, AISI316, AISI316L etc, and the standard is DIN, BS and EN etc. For the construction:We can produce 1*7 & 1*19, which mainly be used in chemical, engineering, aviation, machine, instrument.

For extreme environments exposed to moisture, salt water or corrosive or corrosive chemicals, non-magnectic stainless steel wire ropes are preferred. For mosr applications, galvanized coatings will provide some form of corrosion resistance and still provide the strength and flexibility characteristics desired by the end user.

It is the most cost effective solution. For construction sites, this stainless steel wire rope can be used as a perimeter cable or as a barrier or lashing cable for high-altitude employees. For applicationthat may be used in the field for weeks or months, they can be safely disposed of after the project is completed.

You may know that due to the environmental protection, our Chinese government has ordered the closure of many steel wire rope factory, becauce those factories are without land owership, building ownership and pollution control license. Fortunately, our company has our own factory, the land and buildings are all belong to ourselves, so our factory will not been closed. And in the meanwhile, we have built a new drawing factory in early of this year, so our factory is running normal. so please don"t worry about the delivery time.

Wire ropes can be seen everywhere around us, they are made of strands or bundles of individual wires constructed around an independent core, suitable for construction, industrial, fitness, commercial, architectural, agricultural, and marine rigging applications.

Wire rod is made from high carbon steel wires(0.35 to 0.85 percent carbon) in a hot rolling process of a required diameter, usually from 5.5mm to 8 mm.

Wire rod is drawn to the required diameter by the 1st drawing machine after descaling dust and rust, adding mechanical properties suitable for application.

Positioning the wires different or the same size lay in multiple layers and same direction, or cross lay and diameter is maintained by one-third of the rope size.

So in theory, it is very simple to manufacture wire ropes. However there are many more details that must be closely monitored and controlled, and this requires time and experienced personnel since it is a super complicated project you cannot imagine.

Wire rope is made of plaiting strands of wire – normally medium carbon steel –into a thick cable. The strands are formed around a core. The strands in wire ropes are made of wore twisted together. Strands with smaller diameter wires are less abrasion resistant and more fatigue resistant. Strands made with thicker length of wore are more abrasion resistant and less fatigue resistant.

Left-hand ordinary lay (LHOL) wire rope (close-up). Right-hand lay strands are laid into a left-hand lay rope. Right-hand Lang"s lay (RHLL) wire rope (close-up). Right-hand lay strands are laid into a right-hand lay rope.

Left hand lay or right hand lay describe the manner in which the strands are laid to form the rope. To determine the lay of strands in the rope, a viewer looks at the rope as it points away from them. If the strands appear to turn in a clockwise direction, or like a right-hand thread, as the strands progress away from the viewer, the rope has a right hand lay. The picture of steel wire rope on this page shows a rope with right hand lay. If the strands appear to turn in an anti-clockwise direction, or like a left-hand thread, as the strands progress away from the viewer, the rope has a left hand lay.

Ordinary and Lang"s lay describe the manner in which the wires are laid to form a strand of the wire rope. To determine which has been used first identify if left or right hand lay has been used to make the rope. Then identify if a right or left hand lay has been used to twist the wires in each strand. Ordinary lay The lay of wires in each strand is in the opposite direction to the lay of the strands that form the wire.

Alternate lay The lay of wires in the strands alternate around the rope between being in the opposite and same direction to the lay of the strands that form the wire rope.

The specification of a wire rope type – including the number of wires per strand, the number of strands, and the lay of the rope – is documented using a commonly accepted coding system, consisting of a number of abbreviations.

This is easily demonstrated with a simple example. The rope shown in the figure "Wire rope construction" is designated thus: 6x19 FC RH OL FSWR 6 Number of strands that make up the rope

Each of the sections of the wire rope designation described above is variable. There are therefore a large number of combinations of wire rope that can be specified in this manner. The following abbreviations are commonly used to specify a wire rope. Abbr. Description

The end of a wire rope tends to fray readily, and cannot be easily connected to plant and equipment. A number of different mechanisms exist to secure the ends of wire ropes to make them more useful. The most common and useful type of end fitting for a wire rope is when the end is turned back to form a loop. The loose end is then fixed by any number of methods back to the wire rope.

When the wire rope is terminated with a loop, there is a risk that the wire rope can bend too tightly, especially when the loop is connected to a device that spreads the load over a relatively small area. A thimble can be installed inside the loop to preserve the natural shape of the loop, and protect the cable from pinching and abrasion on the inside of the loop. The use of thimbles in loops is industry best practice. The thimble prevents the load from coming into direct contact with the wires.

A wire rope clamp, also called a clip, is used to fix the loose end of the loop back to the wire rope. It usually consists of a u-shaped bolt, a forged saddle and two nuts. The two layers of wire rope are placed in the u-bolt. The saddle is then fitted over the ropes on to the bolt (the saddle includes two holes to fit to the u-bolt). The nuts secure the arrangement in place. Three or more clamps are usually used to terminate a wire rope.

Swaging is a method of wire rope termination that refers to the installation technique. The purpose of swaging wire rope fittings is to connect two wire rope ends together, or to otherwise terminate one end of wire rope to something else. A mechanical or hydraulic swager is used to compress and deform the fitting, creating a permanent connection. There are many types of swaged fittings. Threaded Studs, Ferrules, Sockets, and Sleeves a few examples.

A socket termination is useful when the fitting needs to be replaced frequently. For example, if the end of a wire rope is in a high-wear region, the rope may be periodically trimmed, requiring the termination hardware to be removed and reapplied. An example of this is on the ends of the drag ropes on a dragline. The end loop of the wire rope enters a tapered opening in the socket, wrapped around a separate component called the wedge. The arrangement is knocked in place, and load gradually eased onto the rope. As the load increases on the wire rope, the wedge become more secure, gripping the rope tighter.

They say you should never visit the sausage factory, and that may be true, but the wilfully ignorant are not to be trusted, and steel wire rope is certainly a special type of sausage. It was a visit that put me through the emotional spectrum, from disinterested to bemused, to bewildered, and finally awed at the sheer scale of the operation. It’s a little bit like when you find out where babies come from: Horrifying and weird to begin with, but before long you find yourself utterly fascinated…

Flexible steel wire rope has been one of the mainstays of heavy industry for more than a hundred years. Whether you want to lash down scaff planks, carry out lifting and cranage, use draglines for surface mining, or even pull down a massive statue of Saddam Hussein, wire rope has thousands of applications.

The Wirerope Works factory in Williamsport, Pennsylvania has a long history of producing this essential component of progress in the 20th century, and although cheaper imports from China and India continue to flood the market, the caretakers of the Bethlehem Wire Rope brand are still proud to produce a product of the highest quality on local labour and quality materials.

Based in Lycoming County in Pennsylvania, Wirerope Works (WRW) began its life as the Morrison Patent Wire Rope Company in 1886. The original mill was built upstream on the banks of the Susquehanna River to service the softwood logging industry, however regular flooding led to the relocation and inevitable expansion of the factory in the town of Williamsport.

The design and manufacture of steel wire rope was no longer in its infancy at that stage. The first practical use of steel rope in 1834 was credited to a German mining official named Wilhelm August Julius Albert, who worked at the Clausthal silver mines in Saxony.

Up until that point, all mining haulage was done with hemp fibre rope or chains. In the humid, damp conditions of an underground mine, moisture would cause the ropes to perish from rot, the gradual deterioration reducing their load bearing capacity, so they required frequent replacement.

Chains at that time were no better in terms of safety, as the Bessemer process for making steel was not invented until 1855. Iron chains lacked elasticity, but were also metallurgically inconsistent and therefore, unreliable. A single weak link could make a chain prone to catastrophic failure without warning, and there was no way of knowing which might be the weakest.

That first incarnation of modern steel wire rope was extremely effective for heavy haulage, and much more reliable than rope or chain. Albert Rope, as it came to be known, was a simple construction of three 3.5mm gauge wrought-iron wires, hand-wound into strands, with three or four of those strands wound into a single rope. However, Albert rope lacked the flexibility of rope or chain, meaning it couldn’t be drawn through a pulley sheave, and its use stopped in the 1850s.

But the idea for wire rope had already caught on in England, where thinner wires were woven around a fibre core, with six of those strands woven around a central fibre core, resulting in a more flexible product. This design, as well as a mechanical system for its construction (called a strander), was patented by Robert Newall, who brought the new technology to America, and the boom-time economy of the California Gold Rush.

However, it was in Pennsylvania where a German-born engineer and surveyor named John Roebling began to develop ropes which were entirely constructed of wire. Roebling used a 6/19 construction (6 strands; 19 wires per strand). A strand built of 19 wires of the same gauge resulted in a hexagonal profile, and desiring a round shape Roebling conceived of using three different gauges of wire to achieve that result. The effect of this was to reduce the space inside the rope, tightly packing the wires together, which gave the rope greater stability under load.

With massive demand for coal haulage in Pennsylvania, as well as cable car applications for public transportation, and most importantly civil engineering projects to service, Roebling set up a wire rope factory in 1849 in Trenton, New Jersey. But he wasn’t the first to invest in a factory like that: Other people had the same idea, and wire rope mills were starting to pop up around the United States. In only 14 years wire rope had gone from a hand-made experiment in a German silver mine, to a globally recognised tool of industry with high demand for scaled-up production.

If Roebling had any hubris about cashing in on this amazing new invention, you could be forgiven for thinking it was a little dampened when his arm and shoulder were horrifically mangled in an accident with one of his stranding machines. But it would seem that Roebling’s interest in wire rope was not strictly for profit, however, as he had for some time harboured a bit of an obsession with sketching suspension bridges. He was a big fan of the expansionist philosophy of Manifest Destiny, and had been very keen on establishing a utopian settlement called Germania (now the town of Saxonburg), where people like him trying to escape the brutal oppression of post-Prussian War Europe could be free to make sauerkraut and smoked pork products, unmolested by the authorities.

But Roebling recovered from his injuries, his factory continued to produce wire rope, and he designed and built a number of suspension bridges using his own product right up until he began design work for the Brooklyn Bridge. Unfortunately, Roebling managed to get his foot crushed by a ferry while standing on a dock trying to work out where the bridge should go. He died of tetanus 24 days later, but his son Washington went on to complete the Brooklyn Bridge project, while his son Charles would invent an 80 tonne wire rope machine.

By 1886, the year the Brooklyn Bridge was opened, a venture like setting up a wire rope factory in Pennsylvania was not at all a bad way to invest $100,000 (probably about $US3 million today), and that is precisely what three businessmen from Williamsport did.

Morrison Patent was changed to the Williamsport Wire Rope Company in 1888, manufacturing steel and galvanised wire rope “from one-eighth of an inch to two and one-half inches in diameter, and any length up to two miles in one continuous piece”, according to an 1892 history of Lycoming County.

The lumber boom in Lycoming peaked in 1891, and the neighbouring Indiana County saw a coal-mining boom start in 1900, so the industrial economy was perfect for the growth of the Williamsport rope mill. A new wire mill was built in 1916, and the current rope mill was built in 1928, which was pretty poor timing considering the Great Depression would start the next year.

By 2004, the Williamsport site had been bought and sold a number of times, changing company names like a serial divorcee, acquiring assets from other defunct companies such as Roebling Wire Rope (the company started by John Roebling in 1849) but always keeping the Bethlehem Wire Rope brand, which became synonymous with top quality steel cable, and is still proudly emblazoned on their rope spools to this day.

In 2002 Williamsport Wirerope Works bought out the bankrupt Paulsen Wire Rope, a rope mill located in nearby Sunbury, and continued to produce under the Paulsen name. But by 2003 the company was also in financial strife, and the management were looking for another buyer who could bail out the company and keep the 600,000 square foot Bethlehem factory running.

The US wire rope manufacturing industry had changed dramatically over the course of 100 years. From an exciting new industry that would allow explosive growth in the productivity of coal mining through the development of dragline surface mining operations in the early 20th century, as well as enabling some of the biggest civil engineering projects ever seen since the Pyramids of Giza, the US stable of 27 wire rope companies had been consolidated down to just three names: Bridon, WireCo, and Bethlehem.

Bridon is another Pennsylvania company, based 100 kilometres away in Wilkes-Barre. Unlike Williamsport which remained a local manufacturer, Bridon expanded rapidly, acquiring other wire rope companies and branching out across the world, developing into a massive, multinational conglomerate, as did WireCo Worldgroup.

With two global entities for domestic competition, Bethlehem also faced increasing pressure from low-cost offshore wire rope producers in countries like China, Korea and India.

Present executive vice-president Lamar J Richards remembers circumstances were looking grim for the Bethlehem brand and for the local employees, with a bid for takeover by Pennsylvania, USA and world market rival WireCo Worldgroup in late 2003.

“Instructions from the ownership at the time were, because we were about to be bought by a competitor we really weren’t going to be making wire, so we had to get rid of all the raw material, the rod, our starting point for the wire,” he said.

But I didn’t know any of those things when I found myself standing, probably in the same spot as Mr Saltsgiver did when starting his tour, right there in the foyer of the single largest wire rope manufacturing facility in North America on a muggy Thursday morning. I had arrived at the factory with a junket of assorted journalists, exhausted from touring a gamut of other factories and fighting off a particularly vicious head cold, quite oblivious to the fact that our tour bus had, having dropped us off, already left with my camera bag still on board. Perhaps one could have forgiven me for being a little out of sorts at first. But not for long…

Walking into the front offices of Wirerope Works on Maynard Street, it’s clear there’s pride in the product here. Foot-long samples of rope in varying configurations and gauges lie on polished timber plinths in the foyer, cleaned of oil with sharp edges ground smooth for safe handling by visitors.

On the walls hang photographs of major construction projects which were supplied with Bethlehem brand wire rope: Madison Square Gardens, the restringing of the Brooklyn Bridge, the Niagara Falls tightrope.

Lamar J. Richards, the executive vice president of Wirerope Works, explains to us some of the history of the plant (see Australian Mining February 2016), but one of the most touching stories he tells us is about how the present owner, Tom Saltsgiver, came to buy the company and keep it alive for the sake of the local economy in Williamsport.

“And my family, they said, ‘We don’t know anything about the steel business, don’t do it, we know modular homes we’ve made a good living doing that, don’t throw your money away here’.”

As it turned out, the newly renamed Wirerope Works became profitable after 18 months of capital support. Shortly after that, the housing bubble burst.

One of the first things shown to us is the floor. The factory is tiled with timber bricks, grain pointing upward and creating a very unique effect where the timber had been polished by decades of wear. The timber floors are a result of Williamsport’s logging history, when wooden blocks were cheap and readily available in bulk. To this day when any flooring needs repairs or replacement, Wirerope Works still uses the original material. To walk on it is remarkably different from concrete, and where I can compare the two it is noticeably easier underfoot. Bear in mind the factory is 620,000 square feet, so a lot of what essentially was scrap lumber had been put to good use.

First we are shown the raw material: 4mm steel wire in loose looking coils about 6 foot across, lifted by forklifts and taken through to a hydrochloric acid bath which will strip off any contaminants. Having been battling a common cold for a few days, I didn’t need to be told the fizzing pool before me was acid. Plumes of vapour were pouring off the bath, and before I could think of doing anything about it the congestion in my head loosened and poured down the back of my throat, and I suddenly I could breathe more clearly and easily than I had done for days! I realised it was the corrosive vapour that had cleared my head, and it might soon start to work on the tissues of my sinus. I tried to hold my breath while our host laughed and tried to explain, incoherently over the roar of the factory, the process of treating the raw material.

We all back away from the deadly head-cold cure and are led to the furnace, where 12 of the washed coils are set up to feed wire through an oven blazing at 1000 degrees Celcius, only 360 degrees shy of melting point. I realise wearing my jacket, despite the cool Pennsylvania humidity, was not the smartest thing in the world to do and we walk past the contained inferno, pouring with sweat.

It’s becoming amply clear to me that this is an extremely dangerous workplace, and we continue to the other side of the furnace where the cherry glowing wires are fed down into a simmering oil bath for quenching.

We file past, only a couple of feet from the long vat of hellbroth with no rails or guards and I think to myself, ‘this must be the single most dangerous thing I have ever stood near’. Having been a labourer and rigger for most of my adult life, I have certainly worked in some unsafe conditions, from high rise buildings with no fall arrest equipment to a uranium mine with no proper PPE, but even those experiences didn’t seem to come close to standing next to this long vat of near-boiling oil. What would happen if one of us stumbled, reaching out for grip and finding only oil that could burn off a limb in seconds, or worse, what if one could fall in altogether! I reassured myself a victim of clumsiness would pass out almost instantly from the shock of the burn. Small comfort as we tried to stay as far away from the vat as possible, with a few feet of leeway for space.

Once cool enough, the wire passes through hydrochloric acid to wash off all traces of contaminant, and I hold my breath as we walk the length of the pool, our host taking deep breaths as if it were fresh spring air and not lung melting fumes, laughing as he watches the visitors squirm… Does he know something I don’t? I sure hope so.

A coating of zinc phosphate, another rinse, and another final coating prepares the wire for extrusion, which has two key functions. The most obvious is for achieving the correct gauge of wire required for twisting into the various rope products, but extrusion also means the steel wire is stretched to align the structure of the steel to align in a single direction, which strengthens and increases the breaking strain of each wire.

However, the most important part of all of this is the stranding process, and here is where my reactions turn from shock to awe. As a rigger using steel wire rope on a daily basis for slinging, I had often wondered how the rope was produced, and here it was before my eyes: The factory floor – acres of it – was full of lines of planetary stranders, all with sets of wires in large bobbins, as many as 64 wires on a single machine, feeding into a single, oily strand of rope. The factory had machines of all sizes hard at work, furiously spinning to produce the some 1200 different combinations of wire rope that come out of the factory every three months.

Finally, we come to the heart of the factory: We stand, astonished, gazing up at the 12 foot tall, 800 tonne closing machine, designed to produce the 7 inch rope for dragline boom pendants, and construction cable like that used to build the Brooklyn Bridge. The already huge strands are all dragged into a central point, slowly weaving the helical pattern of wires around a hefty centre rope into a single massive cable which will one day end up on a dragline somewhere in the world.

With a history spanning 120 years, the Wirerope Works factory has seen plenty of hard times, but it’s also had a lot of luck. With good leadership at the helm from the likes of Saltsgiver and Richards, and ongoing demand for steel wire rope, the old Williamsport factory could continue to produce its quality bespoke products for another 120 years.

Steel wire rope is consisted of several strands of metal wire twisted into a helix. It is used for lifting, traction, taut and bearing in the material handling. And it has advantages of high strength, light weight, safe and stable work.

We can produce various of steel wire rope according to our national standards such as GB8919, GB/T20118, GB/T20067 and also international standards ISO, ASTM, EN, JIS and API etc. GotAPI, DNV, LR, BV, CCS, MA and KA certification,which assure good quality control.

The performance of steel wire rope to load is mainly determined by steel wire. Steel wire rope are normally made of carbon steel or alloy steel, which makes it has high strength and toughness. And the surface treatment of it can be finished according to the used environment.

In the cross lay strands, the wires of the different layers cross each other. In the mostly used parallel lay strands, the lay length of all the wire layers is eaqul and the wires of any two superimposed layers are parallel, resulting in linear contact.

The rope core is mainly used to increase the elasticity and thoughness, lubricate steel wire, lighten friction and improve the service life of wire rope. The commonly used types including oganic fibers, such as hemp and cotton, synthetic fiber, asbestos core or soft metal materials.

On how to select different constructions of wire rope, you can refer to GB8918-2006 “ Steel Wire Ropes for Important Purpose ”, and GB/T20018-2006 “ Steel Wire Ropes for General Purposes ”. The technical parameters such as lifting load, safety coefficient, and the lifting capacity of the lifting equipment should be taken into consideration when selecting the strength class of wire rope.

RM2D9B7DA–An old engraving of a giant, hand-powered, wooden foundry crane in the 1800s. It is from a Victorian mechanical engineering book of the 1880s. A crane is a type of machine, generally used a hoist rope, wire ropes or chains, that can be used both to lift and lower materials and also to move them horizontally. The earliest cranes were made from wood, but cast iron, iron and steel took over – as did mechanical power, first provided by steam engines. Sizes of these jib (or post and jib) cranes vary enormously – here this large machine is used to move big sheets of iron or steel.

Stainless steel wire rope is made of stainless steel raw materials by drawing and twisting. It has excellent corrosion resistance, high temperature resistance and low temperature resistance. It is widely used in petrochemical industry, aviation, automobile, fishery, precision instruments, architectural decoration and other industries. After electrolytic polishing, the surface of stainless steel wire rope is brighter and the corrosion resistance is greatly enhanced. After low-temperature heat treatment, the wire rope can achieve higher strength. There are many classification methods of stainless steel wire rope, such as steel grade, construction/structure, laying/twist direction, surface, application and breaking load/strength. The most common used steel grade is SUS304/SS304 and SUS316/SS316.

The Stainless Steel Wire Rope of Shanghai BISCO International Corporation has the advantages of high dimensional accuracy, excellent surface quality, high brightness and stable mechanical properties. If there is a need of this product, please feel free to contact us, we will provide you with a quotation within 24 hours since receiving your inquiry.

6. Constructional Symbol: 1X3, 1X7, 1X19, 1X37, 3X7, 6X7+FC, 7X7, 6X19+FC, 7X19, 6X36SW+IWRC, 6X37+FC, 7X37, 8X19, 19X7 (Single Layer、Filler Wire、Seale、Warrington、Combination)…

Stainless steel wire rope has many characteristics such as excellent corrosion resistance, heat resistance, low temperature resistance, good fatigue resistance, high breaking force, long service life and durability. It is widely used in coal, petroleum, metallurgy, chemical industry, machinery, construction, ships, aviation, vehicles, bridges, cableways, control lines, electric power, rubber, military industry, medical treatment, water conservancy, fishery and light industry…etc. Stainless steel wire rope can be produced according to international standards such as ISO, BS, DIN, JIS, ABS and LR.

2. Stainless Steel Wire Rope for Elevator: it is used in elevator equipment carrying people and things in high-rise buildings. It is required to have a tight and soft structure and small structural elongation. It usually adopts 8-strand structure

3. Aviation Stainless Steel Wire Rope: it is used for aircraft aerial rope or operation aerial rope, which is required to have high fatigue performance and corrosion resistance

5. Steel Wire Rope for Aerial Cableway and Cable Car: it is used for air transportation track. With cable car as the means of transportation, the steel wire rope is required to have a large safety factor, corrosion resistance and smooth surface of stainless steel wire rope

6. Hoisting Stainless Steel Wire Rope: it is required that the wire rope has high tensile strength, good flexibility, no rotation, distortion fatigue resistance and no looseness

7. Stainless Steel Wire Rope for Fishery: it is used for trawl, fixed net, rolling net, etc. it works in rivers, lakes and seawater environment, and requires good corrosion resistance and flexibility

Hold everything together with the Jumbl 316 Grade Stainless-Steel Wire Rope, 100 Ft. Use this heavy-duty rope when working with hefty materials. This stainless-steel wire rope is great for fencing and hanging things you want to stay perfectly in place. With breaking strength of 1,510 lbs. this is the type of reliable rope you do not have to worry about snapping.

Viable anywhere needed, use this stainless-steel cable indoors or outdoors. Stick with Jumbl to get strong, sturdy wire rope you can depend on for all your renovating and construction needs.

Braided to last longer – This durable wire rope is made up of 7 x 7 stainless-steel strands. These strands are braided together to create rope built to last.

For construction needs – Great for making renovations inside or outside the home. Hang up your heavy tools or thread the railing of your stairs with this rope.

Steel wire ropes have important applications in mine lifting, cable-stayed bridges, metallurgy, elevators, and so on. They are widely used due to their high strength, light weight, reliability, and efficiency [1]. Since wire ropes usually work in harsh environments, although they suffer from a variety of types of damage such as broken wire and wear, which affects the safety of production and even threatens the lives of workers [2]. To avoid accidents, manual inspection and regular replacement are generally used in engineering. However, manual inspection is time-consuming and laborious, and regular replacement usually causes great economic waste. According to a survey, more than 70% of replaced wire ropes still have initial breaking strength [3]. Therefore, it is of great importance to develop scientific and effective devices to inspect steel wire ropes.

There are two types of defects of steel wire ropes, loss of metallic cross-sectional area (LMA) and a localized fault (LF), and broken wire is the most typical outcome of LF. Among the various nondestructive testing techniques, magnetic flux leakage (MFL) method is most economical and effective for broken wire detection [4,5,6,7,8]. The basic principle of the MFL method is shown in Figure 1, where the permanent magnet magnetizes part of the wire rope to saturation, and a closed magnetic circuit is formed between the wire rope, the magnet and the yoke. When no damage is present, most of the magnetic induction lines pass through the inside of the wire rope. When there is a damage such as broken wire, the magnetic resistance of the damaged position increases, and part of the magnetic induction line leaks out to form the MFL. Magnetic sensitive elements are placed between the poles of the magnet to sense the MFL signal. The condition of the wire rope can be determined according to the received signal.

For decades, many experts and scholars have done a lot of research on the design of damage detecting sensors based on the MFL method [9,10,11,12,13]. Cao Y.N. et al. [9] proposed an approach for detecting LF of steel wire ropes using an annular array of Hall components. A back propagation (BP) network is used to classify the faults. This method can differentiate the degree and the width of local defects. Zhang J. et al. [10] applied the giant magneto-resistance (GMR) sensor to the detection of LF and LMA of the wire rope. Through the use of compressed sensing wavelet filtering and BP neural network, the accuracy and reliability of MFL sensor is improved. Wu B. [13] designed an MFL sensor based on tunnel magneto-resistive device. A blind hole with dimension of 0.3 mm in both depth and diameter is detectable for the sensor. The axial resolution to two adjacent notches with a width of 0.2 mm of the TMR-based MFL sensor can be less than 2.5 mm. However, arranging annular arrays of Hall components undoubtedly increases the complexity of the signal processing. Using magneto-resistive sensors can improve the sensitivity of the sensor, but it is difficult to be applied to actual inspections due to the micron-level requirements of the lift-off [13]. Therefore, designing a sensor that can be applied to the detection in actual engineering and is both simple and effective, has always been a problem for the condition monitoring of wire ropes.

The magnetic concentrating detection technology provides a new direction for the development of MFL sensors. The detection of wire ropes usually requires the arrangement of a plurality of magnetic sensitive elements. Especially for the large diameter wire ropes, it usually needs dozens of magnetic sensors, which greatly increases the difficulty of signal processing in the later stage. The magnetic concentrating principle can realize the leak-free detection of large diameter wire ropes through a small number of magnetic sensitive elements [14,15]. Kang et al. [14] theoretically analyzed the feasibility of magnetic concentrating detection. It is proved by calculation that the magnetic concentrator can collect the MFL and guide it into the Hall component through the bridge between the concentrators to realize the collection of weak leakage flux. At the same time, it can eliminate the strand-waveform noise of wire ropes and improve signal-to-noise ratio of the MFL signal. Wang et al. [15] analyzed the performance of the magnetic concentrators on collecting the MFL by finite element simulation and proposed the structure which is suitable for collecting the magnetic leakage flux. The structure was verified by experiments, which further promoted the development of the magnetic concentrating detection.

In this study, a sensor, which is constructed of ring-shaped magnets, a yoke, and a magnetic concentrator, is designed to detect broken wires of steel wire ropes. We optimized the structural parameters of the circumferential multi-circuit permanent magnet exciter (CMPME) and analyzed the performance of the magnetic concentrator on collecting MFL through the finite element method. Finally, the proposed sensor is applied in an experiment for broken wire detection. The induced MFL signal can be clearly recognized and the signal-to-noise ratio of the MFL signal is improved by discrete wavelet transform (DWT).

Wire ropes are structural components made of twisted wire that are widely employed in diverse areas. The safe usage of wire ropes is directly related to the production lifetime and personnel safety. Therefore, it is of great significance to develop an online detection and quantitative inspection system for wire ropes [1]. ElectroMagnetic Testing (EMT), the advantages of which include low cost, high reliability, and suitability for online detection of wire rope, has been widely used in wire rope application. EMTs include eddy current testing, magnetic particle testing, Magnetic Flux Leakage (MFL) detection, magnetic memory detection, microwave detection, and other methods. Among these, the MFL method can detect the surface and internal defects of wire rope, and has been greatly developed for its simple structure and portability [2].

In a traditional MFL detection, wire rope is magnetized to saturation, after which a magnetic probe is used to measure the MFL distribution. According to the form of the magnetic field source, there are two techniques: coil magnetization [3,4] and permanent magnet magnetization [5,6,7,8,9,10]. Singh [3] designed a magnetized device consisting of a variable-current saddle-shaped coil. This apparatus can be adjusted by controlling the magnitude of the current, but the device cannot be continuously used for the massive heating of the coil. Jomdecha et al. [4] improved a coil device of solenoid structure instead of traditional coil magnetizer. The magnetic field strength can be adjusted by changing the magnetizing current or magnetizing coil number. The multiple symmetrical yoke structures were composed of circumferentially distributed wire rope to magnetize its uniform saturation [5,6,7,8]. Wang et al. [9] considered the effects of different lift-off distances on detection accuracy during the magnetization process, and proposed an improved magnetization device. Xu et al. [11] used the finite element analysis method to optimize the structure of the excitation device, which was then validated by the experiment.

In a testing system, the magnetic field is converted into an electrical signal by a magnetic-to-electric convertor, such as an induction coil, a fluxgate, a Hall element, or a magnetoresistive sensor. Cao [12] proposed a detection device based on a Printed Circuit Board (PCB) split differential coil, obtaining a sum of MFL circumferential distribution signals. The device is useful for a certain span in the axial direction of the wire rope, but it is not sensitive to small width defects and circumferential defect information. Jomdecha et al. [4] improved the traditional induction coil by designing an induction coil array, with coils arranged on the circumferential wire rope. This system solved the problem of MFL circumferential information loss. Zhao et al. [13] designed a detection device in which 30 Hall sensors evenly surround the circumferential wire rope. This device can effectively obtain the information of the circumferential MFL distribution, but the Signal-to-Noise Ratio (SNR) of the collected signal is low. Peterka et al. [14] presented the results obtained by tracking the magnetic flux around the cable end and the signal runs from a particular design. Additionally, they investigated scanning elements placed above artificial defects created close to the cable end.

The signal that is collected by magnetic sensors contains ample background noise, so it is necessary to filter system noise. Cao et al. [12] proposed an algorithm for adaptive parameter spatial notch filtering to suppress strand wave, and the wavelet packet was used to filter out the high-frequency random noise. Zhang et al. [15,16] used the wavelet based on compressed sensing to denoise the strand wave and high-frequency noise, and then further proposed a channel-balance method based on the Hilbert-Huang transformation. Zhang et al. [17] used a spatial filter to reduce noise and smoothen the defect image. Zhang et al. [18] pretreated the MFL grayscale and effectively suppressed the noise interference. Tian et al. [19] combined the wavelet transform and the morphological transform to create a morphological filter algorithm that suppressed the interference associated with the baseline drift in the wire rope signal.

There are some problems among the existing MFL methods for defect detection in wire ropes:the excitation devices are cumbersome and inconvenient, the defect cannot be positioned in the circumferential direction, the wire rope is magnetized unevenly, and the SNR is low. A device to detect wire rope surface remanence strength was designed to solve these problems, and this solution is described in this paper. The wire rope was magnetized by permanent magnets, and the MFL information of the wire rope surface was collected after magnetization with giant magnetoresistive sensors, arranged evenly around the circumference of the wire rope. A wavelet filtering method based on Ensemble Empirical Mode Decomposition (EEMD) was used to denoise the original signal. The two-dimensional defect signal was processed and analyzed by digital image technology. To achieve quantitative classification, the defect image characteristics were extracted to express the MFL distribution information. The processing data were normalized to obtain the MFL grayscale image. The cubic spline interpolation was used to improve the circumferential resolution. The method of modulus maxima was used to locate and segment defects from the MFL image. The wavelet super-resolution reconstruction method was used to improve the resolution of the segmented image. Image descriptions of area, rectangle, elongation, and seven invariant moments were extracted as the feature vector of the defect, which was the input of a Back Propagation (BP) neural network, used to classify the defects.

We supply the cable to the largest wholesale companies and manufacturers in Russia and Europe. Our customers are always confident in the quality of our product, because of strict control of manufacturing steel chain and galvanized wire rope. You can be sure of the quality of our products.

Our factory has a full production cycle. We ourselves make the wire, and after that we produce a cable and a chain from it. So we can offer very attractive prices to customers. With purchasing steel chain and galvanized wire rope directly from manufacturer, you save considerable funds, which you may convert into your profit or you can reinvestigate it for expansion of your business.

Factory address: NANTONG CITY TONGZHOU ZONE ZHANGZHISHAN TOWN ZHANG CHUAN ROAD NO.6 JIANGSU CHINA© Steel wire rope and steel chain manufacturer in China, 2022