sheave design for wire rope price

Simple machine consisting of a fixed, grooved wheel, sometimes in a block, around which a rope or chain can be run. A simple pulley serves only to change the direction of the applied effort (as in a simple hoist for raising loads). The use of more than one pulley results in a mechanical advantage, so that a given effort can raise a heavier load.

The mechanical advantage depends on the arrangement of the pulleys. For instance, a block and tackle arrangement with three ropes supporting the load will lift it with one-third of the effort needed to lift it directly (if friction is ignored), giving a mechanical advantage of three.

Bairstow Lifting Products Co., Inc. offers a variety of wire rope sheaves from a large line of manufactures to meet OEM replacement specifications. Additionally, we can custom mill a wire rope sheave to you desired measurements, including to OEM specifications, generally faster than one can be obtained by the OEM. Please complete the online .PDF form from the specs tab on the product page and fax or email the form to us. We will return to you promptly with pricing and availability.

Selecting the right size for sheaves will help prevent frequent wire rope damage which in some instances occurs after just one run. Many common operational issues including the wireline getting dislodged or losing its strength are caused by improper sheave sizing and alignment problems. Our experts offer 3 valuable tips to eliminate stress failure, improve equipment safety and efficiency, as well as increase the lifespan of your sheaves and wire rope.

Pay attention to sheave groove size and diameter: When sheaves for your wire rope are too large or too small, there is greater stress on both resulting in spooling trouble and premature wear. For instance, grooves that are too large have proven to cause the wire rope to flatten and unbalance leading to the wire breaking. When properly sized, the groove provides maximum support to the rope lowering the sheave bearing pressure and increasing sheave and rope lifespan. Typically the groove diameter should exceed that of the wire rope by 5% while groove depth should be one-and-a-half times the rope diameter. A groove angle between 30° and 45° offers the best support for the wire rope. Specific dimensions and angles may vary depending on your application.

Ensure sheave groove hardness: The hardness of sheaves is a factor that is often overlooked. Since the wire rope is hard, the pressure it exerts on the groove can lead to corrugations if the sheave is not properly hardened. To avoid this, ensure your steel cable sheaves are flame hardened. (A simple way to determine if your grooves are worn out is by using a sheave gauge.) At Rockett Inc., we can provide flame hardening for wear resistance along the contact area.

Correct sheave groove alignment: Poor alignment of your sheaves wears out the wire rope and sheave flange. This is because the rope comes into constant contact with the flange creating stress on the rope, abrasion damage and fatigue breaks. Any alignment issues should be corrected immediately.

To avoid operational problems, opt for custom made steel sheaves. This way the sheaves for your wire ropes are tailored to your specific requirements instead of the other way around. As an experienced sheave manufacturer with a state-of-the-art facility in Mississippi, Rockett Inc. offers comprehensive custom solutions for diverse industrial and commercial needs.

Should you have a specific requirement, our experienced engineers can work closely with you to design and manufacture the product your application requires. Precision engineering and state-of-the-art metal fabrication equipment result in a closer tolerance fit to the wire rope to reduce fatigue and wear. Inspection at every stage of our manufacturing process ensures that the final output meets your specifications.

Need assistance with designing sheaves for wire rope? We are always happy to help. Our team can work directly from your drawings and specifications, or offer 3D CAD design and engineering support optimized for practical, cost-effective results. Over the years, we have produced the most diverse range of custom steel cable sheaves for our clients across the globe.  Having the ISO 9001:2008 Certification means we take pride in quality and customer satisfaction.

Above all else, we are an engineering firm that can take your technical requirements for sheaves and translate them into cost effective solutions to meet or exceed the performance required of your application. Selection of the proper sheave material plays an important role in ensuring strength, durability, and overall performance in your application. Sheaves Inc. has been the number one source for the wire-rope industry, designing and providing custom engineered wire rope sheaves that meet your specific needs and rigors of your application. Trust our engineering expertise, and let us suggest a suitable material in your next challenging application.

Light weight option for high speed applications. Resistant to chemicals, temperature, and corrosion. Durable in wire and cable processing applications

Our custom process sheaves are most often machined from Gar-Dur, the densest, toughest thermoplastic today. GAR-DUR properties, such as toughness and abrasion resistance with light weight, make it ideal for high speed sheaves processing wire and cable.

Manufacturing methods limit GAR-DUR material to 23″ OD and 2″ OAW. For sheaves beyond those dimensions we use virgin UHMW cut from stress-relieved sheets.

HDPE has similar properties to UHMW but lower properties and prices. Ideal for tubing, hose, synthetic rope, and similar materials that have less demanding wear and load requirements.

Ceram-P is ceramic filled UHMW recommended for high load and severe sliding abrasion. It is a shatter resistant alternative to sintered ceramic but substantially heavier and more expensive than UHMW.

Esheaves.com offers custom solutions engineered to meet the exact requirements of your application. From the strength and durability of a nylon sheave, to the rapid shipping and stock availability of Q sheaves, we will help you meet any challenge. If you don’t see the customizable options you need, we’ll engineer a complete, original solution just for you!

Know the sheave material you need? Visit the eSheaves shop to select from a variety of sizes, materials, and bearing types in stock and ready to ship.

Multi-layer drum systems should use strand- or swage compacted Python® rope constructions having a steel core. The higher fill factor of such rope constructions will offer a greater resistance to crushing and flattening than conventional rope types. This is particularly important for boom hoist ropes on lattice boom cranes at the cross over point from one rope winding to the next.

Cranes equipped with multi-layer drum systems which require rotation-resistant or non-rotating rope are best served with Python Compac® 18 and Python Compac® 35. To further reduce drum crushing have the rope layers wound onto the drum with about 5-10% of the WLL and avoid that the first layer unspools and re-spools without tension. This would cause a ‘soft’ bottom layer which will flatten rather quickly.

The Sheave Gauge is manufactured to Nominal plus 5%, the wire gauge measures the nominal size. When the sheave gauge is placed in the groove, the geometries should match without any space at the sides or bottom.

Our team understands that choosing the right cable assembly manufacturer, and pulleys for your cable assemblies requires thoughtful consideration, from bearing life, to minimum pulley diameter. Let Sava"s engineering expertise guide you toward the best selection of wire rope pulley wheels.

When cable is used over pulleys, the cable life can be significantly prolonged by proper pulley groove design. Laboratory tests on wire rope pulleys prove that improper groove design reduces cable bending life up to 90%. These same tests show that doubling a pulley diameter can increase cable bending life up to thirteen times what is otherwise typical. Also, pulley diameters less than sixteen rope diameters fall into a range in which cable life is relatively low.

The life of steel cable pulleys is reduced as the groove radius changes from the contour of the cable to a flat surface. For maximum cable life, the groove should make contact with the cable on at least 1/3 of the cable circumference.

Sava has been manufacturing the pulleys the world depends upon for almost a half-century. Talk to Sava"s pulleys experts now and build it right the first time.

This construction is used where ropes are dragged on the ground or over rollers, and resistance to wear and abrasion are important factors. The wires are quite large and will stand a great deal of wear. In fact, this construction is sometimes called “coarse laid” because of the large wires. The 6x7 is a stiff rope and needs sheaves and drums of large size. It will not withstand bending stresses as well as ropes with smaller wires. Because of the small number of wires, with the resulting higher percentage of load carried by each wire, a larger factor of safety should be considered with 6x7 ropes than with ropes having a larger number of wires.

The 6x19 Classification of wire rope is the most widely used. With its good combination of flexibility and wear resistance, rope in this class can be suited to the specific needs of diverse kinds of machinery and equipment. The 6x19 Seale construction, with its large outer wires, provides great ruggedness and resistance to abrasion and crushing. However, its resistance to fatigue is somewhat less than that offered by a 6x25 construction. The 6x25 possesses the best combination of flexibility and wear resistance in the 6x19 Class due to the filler wires providing support and imparting stability to the strand. The 6x26 Warrington Seale construction has a high resistance to crushing. This construction is a good choice where the end user needs the wear resistance of a 6x19 Class Rope and the flexibility midway between a 6x19 Class and 6x37 Class rope.

The 6x36 Class of wire rope is characterized by the relatively large number of wires used in each strand. Ropes of this class are among the most flexible available due to the greater number of wires per strand, however their resistance to abrasion is less than ropes in the 6x19 Class. The designation 6x36 is only nominal, as in the case with the 6x19 Class. Improvements in wire rope design, as well as changing machine designs, have resulted in the use of strands with widely varying numbers of wires and a smaller number of available constructions. Typical 6x37 Class constructions include 6x33 for diameters under 1/2", 6x36 Warrington Seale (the most common 6x37 Class construction) offered in diameters 1/2" through 1-5/8", and 6x49 Filler Wire Seale over 1-3/4" diameter.

Alternate Lay, sometimes referred to as reverse lay, is a stranded rope where the type of lay of the outer strands is alternately regular lay followed by lang lay such that three of the outer strands are regular lay and three are lang lay. Alternate lay wire rope has the extra flexibility of lang lay in combination with the structural stability of regular lay. It unites the best features of both types of wire rope. Alternate lay is made with relatively large outer wires to provide increase of abrasion resistance to scrubbing against sheaves and drums. Finer inside wires and flexibility enable alternate lay ropes to absorb severe bending stresses. It is well suited to winding applications where abrasion and crushing can occur. Alternate lay wire rope applications include boom hoists and numerous types of excavating equipment like clamshells, shovels, cranes, winches and scrapers.

The 8x19 Classification rotation resistant ropes are recommended for hoisting unguided loads with a single-part or multipart line. The eight outer strands are manufactured in right lay, with the inner strands being left lay. These ropes are slightly stronger and significantly more rugged than the 19x7 construction. However, the rotation-resistant properties of the 8x19 rotation-resistant ropes are much less than those of the 19x7 construction. These ropes are manufactured in right regular lay in the 8x19 Seale and 8x25 Filler Wire constructions.

19x7 is recommended for hoisting unguided loads with a single-part line. The rotation-resistant properties of this rope are secured by two layers of strands. The inner strands are left lay, while the 12 outer strands are right lay, which enables one layer to counteract the other layer"s rotation. The rotation-resistant characteristics of the 19x7 wire ropes are superior to those of the 8x19 Class wire ropes.

SFP 19 is recommended for both multipart load and single-part fast line applications where rotational stability of the lifted load is needed, such as for use as a long fall on offshore pedestal cranes, rough and all terrain cranes, and crawler cranes. SFP 19 provides:

Fatigue Resistance. Improved fatigue properties are derived through the combination of the flexible 19x19 construction and die drawn strands. The drawn strand surfaces minimize the interstrand and interlayer nicking that take place in round rotation resistant ropes.

Abrasion Resistance. Die drawn ropes provide improved abrasion resistance as compared with round wire ropes because of the greater wire and strand bearing surfaces contacting sheaves and drums.

Resistance to Drum Crushing. SFP 19 wire ropes are resistant to the effects of drum crushing due to the compacted strands and smoothness of the rope surface.

Superior Rotation Resistance. The SFP 35 rope is the most rotation resistant rope manufactured by WW. Due to its rotation resistant properties, SFP 35 may be used with a swivel in both single part and multipart reeving.

Flexibility. SFP 35"s multiple strand construction provides increased flexibility which improves service life and high speed spooling. The compacted compacted multiple strand construction also reduces sheave and drum abrasion and provides excellent resistance to drum crushing.

6-PAC is recommended for use where the rope is subjected to heavy use or where conditions are extremely abusive, such as offshore pedestal, crawler and lattice boom equipped truck crane boom hoist applications. 6-PAC is also recommended for winch lines, overhead cranes, multipart hoist lines where rotation-resistant ropes are not required, and other applications where flexibility, high strength and resistance to crushing are important, and a cost-effective 6-strand rope is desired.

Fatigue Resistance. Improved fatigue properties are derived from the combination of 6-PAC"s flexible constructions and the compacted strands. The compacted strand surface minimizes the interstrand and interlayer nicking that take place in standard 6-strand ropes.

Abrasion Resistance. 6-PAC"s compacted strand design provides improved abrasion resistance as compared to standard 6-strand ropes because of the increased wire and strand surfaces contacting sheaves and drums.

Drum Crushing. 6-PAC dramatically increases the amount of wire contact with the drums and sheaves, reducing the wire rope, sheave and drum wear normally associated with standard wire rope.

Recommended for applications where abrasion and fatigue resistance is required, such as for winch lines, chokers, skylines, and haul backs, as well as any application where a swaged rope is used

8-PAC is recommended for hoist ropes for steel mill ladle cranes and hoist and trolley ropes for container cranes, or other hoisting applications with heavy duty cycles or where severe bending occurs.

Superior Performance. 8-PAC has higher breaking strength and gives superior performance in difficult hoisting applications compared to standard 6-strand and 6-strand compacted ropes.

Abrasion Resistance. 8-PAC compacted strand design provides improved abrasion resistance as compared to standard 6 and 8 strand ropes because of the increased wire and strand surfaces contacting the sheaves and drums.

SUPER-PAC is a double compacted product ideal for applications where abrasion and drum crushing are an issue. When compared with standard ropes, SUPER-PAC provides: Better resistance to multi-layer drum crushing. SUPERPAC dramatically reduces the damage at cross over points on smooth face drums, such as those found on many boom hoist systems on mobile cranes. This is achieved by compaction of the strands and the rope, making a tough but flexible product.

Superior Fatigue Resistance. SUPER-PAC is engineered for overall performance, its wire tensile strength being the key to its superior fatigue resistant properties. In addition to contribution to SUPERPAC’s EEEIP breaking strength, the wire used in the manufacture of SUPER-PAC remains ductile, minimizing the occurrences of external and internal wire breaks caused by operating stresses.

TRIPLE-PAC was developed for the most demanding hoist applications. TRIPLE-PAC offers the extra high strength and crushing resistance needed for applications such as boom hoist ropes, boom pendants and multipart load lines.

TRIPLE-PAC provides superior abrasion and fatigue resistance as compared with most compacted ropes due to WW’s unique design of compacting the IWRC, individual strands and the rope itself. Other benefits include:

High Strength. TRIPLE-PAC is designed to provide a nominal strength of 35% above EIP. WW achieves this strength through selected grades of steel and TRIPLEPAC’s unique design and manufacturing processes.

Superior Resistance to Multilayer Drum Crushing. TRIPLE-PAC provides superior resistance to crushing through its design. Its triple compaction provides a denser cross section, enabling the rope to withstand the rigors of multilayer spooling. Damage at the cross over points is also significantly reduced.

BXL is infused with a specially- engineered polymer, creating a well-balanced matrix. BXL is recommended for numerous hoist, marine and logging rope applications. BXL provides: Fatigue Resistance. Improved fatigue resistance is derived from the cushioning and dampening effect of the polymer on the wires and strands. BXL also evenly distributes stresses which may lead to fatigue breaks.

Abrasion Resistance. The polymer acts as a barrier between the individual strands, preventing penetration of any adverse material. BXL distributes and reduces contact stresses between the rope and sheave, reducing wire rope wear.

Service Life. BXL minimizes corrugation and wear normally associated with standard rope usage by restricting water and dirt penetration and eliminating pickup of abrasive materials.

This rope is particularly suitable where severe conditions of crushing and abrasion are encountered on the drum or where a higher strength design factor is required than can be obtained with a similar round rope.

The triangular strand shape not only provides better resistance to crushing, but also offers a greater exposed surface area for contact with sheaves, drums or underlying layers of spooled rope. This feature, in connection with the use of Lang lay construction, distributes the abrasive wear over a greater number and length of wires. The smooth surface of the rope also helps minimize wear on drums and sheaves.

ROEPAC is a three strand compacted rope with high breaking strength and stable construction making it perfect as a pulling rope for overhead transmission lines and underground conduits. It’s flexibility and flat surface provides snag-free guidance of the attached lines.

Abrasion Resistance. Compacted design provides improved abrasion resistance compared to standard 6 strand ropes because of the increased wire and strand surfaces contacting the sheaves and drum.

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Johnson Wire Rope Sheaves are industry proven and are available in sizes ranging from 3" to 108", in over 250 standard models. Cost efficient, custom designs are available, with no upfront tooling or pattern charges and no premium price for small order quantities. 16" to 108" O.D. Sheaves have flame hardened, precision grooves for slow, even wear and long rope life. The integrity of Johnson’s single disc forged steel construction provides sheaves with superior strength.