Wire Rope Research Articles

Nonlinear broadband vibration reduction of nitinol-steel wire rope: Mechanical parameters determination and theoretical-experimental validation

This study validates the nonlinear broadband vibration reduction capability of Nitinol steel wire rope (NiTi-ST). Hysteresis tests on NiTi-ST provide hysteresis force-displacement data, and mechanical parameter calculations are performed by developing a fitting model. A dynamic model of a composite laminated cantilever plate embedded with NiTi-ST is developed. The modal analysis is performed using the Rayleigh-Ritz method, and accurate modal functions are obtained. The dynamical equations are solved using the Galerkin truncation and harmonic balance methods. Experimental results demonstrate NiTi-ST’s global broadband vibration reduction at various temperatures, with a decrease in effectiveness as temperature rises. These experimental results are consistent with the theoretical analysis. This study firstly experimentally validates NiTi-ST’s nonlinear behavior, and provides technical support for NiTi-ST’s use as a nonlinear vibration reduction device.

Estimation of Early Corrosion Mechanism on the Upper Surface of Wire Ropes in Suspension Bridges

This study is focused on the heterogeneous corrosion phenomenon of the general segment of suspension bridge main cables in mountainous/plain areas, specifically focusing on the uppermost surface. The primary objective of this research is to elucidate the corrosion mechanism by investigating the corrosion environment and performing corrosion acceleration tests using simulated ropes. Consequently, it has been revealed that during the summer season, the surface temperature of the rope reaches approximately 65°C, corresponding to the zenith of zinc corrosion rates. Moreover, in the upper surface of the rope, which is particularly susceptible to the influence of solar radiation, it has been disclosed that condensation occurs as a non-rainfall-related factor, creating an environment conducive to condensation. These factors suggest that the moisture supplied to the upper surface and the residue of corrosive elements exert an influence on the skewed corrosion mechanism of the rope surface.

Adaptive fast Walsh-Hadamard transform for magnetic flux leakage signal of broken wire damage extraction under noise background

ABSTRACT Steel wire rope usually works in harsh environments, making it prone to damage during frequent use. Magnetic flux leakage testing is an important way of non-destructive testing, preventing some major accidents of hoist equipment by identifying the damage to steel wire ropes. Whereas, the harsh environment usually generates noise and results in difficulty in extracting the damage features of the magnetic flux leakage signal, which makes it hard to identify the damage. The fast Walsh-Hadamard transform is widely used in signal processing. The denoising effect depends closely on the transform coefficients. If the transformation coefficients can be adaptively retained, better denoising effects can be achieved. Therefore, we propose the adaptive fast Walsh-Hadamard transform to extract the magnetic flux leakage signal of steel wire rope under noise background. Using the cross-correlation co efficient and the similarity of the greyscale histogram as the indexes, the Fast Walsh-Hadamard transform combines the adaptive particle swarm optimisation to adaptively retain the optimal transformation coefficient and then gets the optimal denoising signal. Meanwhile, compared to wavelet denoising methods, the adaptive fast Walsh-Hadamard transform can effectively improve denoising performance in peak-to-peak reductivity and can be successfully used in steel wire rope damage extraction.

A novel fiber-reinforced polymer rope: Concept design and experimental evaluation

The present study proposes using a twisted rope with flexible fiber-reinforced polymers (FRPs) instead of wire rope and synthetic rope in environments requiring high load-bearing capacity and corrosion resistance. Resin toughening modification was conducted to manufacture flexible FRPs, and experimental evaluations were performed to assess the tensile and flexural properties of the impregnated fiber bundles (IFBs), as well as the tensile behaviors of the seven-IFB strands and the seven-strand ropes. The results demonstrated that the modified epoxy resin exhibited a decrease in both strength and elastic modulus, while its ductility was enhanced. Tensile and bending experiments confirmed that incorporating an additional 10% of Qishi toughener (QS-VA-3) was the optimal choice for producing low-modulus and high-toughness resins. Although the tensile properties of resin modified IFBs may show a slight reduction, their repeated bending behavior can be significantly improved. The tensile load-displacement curves of the FRP strand and rope displayed a linear increasing trend and experienced intermediate fracture failure, resembling that observed in IFBs. Furthermore, it was found that the tensile strength and elastic modulus of the strand decreased with an increase in lay length. The secondary twisting can enhance the tensile behavior of ropes compared to strands with equivalent lay lengths.

Research on quantitative identification method for wire rope wire breakage damage signals based on multi-decomposition information fusion

Steel wire ropes are widely used in various fields, such as mining, elevators, and cable cars. However, their long-term use can lead to wire breakage, posing safety risks. The detection of wire breakages in steel wire ropes is crucial. This study addresses the shortcomings of existing quantitative identification methods for steel wire rope damage detection and proposes a novel model for fusion-based classification and recognition of wire rope damage. This model first combines the continuous wavelet transform and variational mode decomposition for feature extraction. Subsequently, it utilized convolutional neural networks to learn data features and introduced an attention mechanism to weigh and select the fused data. The final output provides the classification results, aiming to enhance the classification accuracy. Comparative experiments and ablation studies were conducted using the memory networks, autoencoder, and support vector machine models. The experimental results demonstrate the superiority of the proposed model regarding feature extraction, classification accuracy, and automation. The model achieved an accuracy rate of 94.44 % when classifying the nine types of wire breakages. This study presents an effective approach for signal processing and damage classification in steel wire rope damage detection, which is crucial for improving the reliability of wire breakage detection in steel wire ropes.

Research and application on intelligent monitoring and early warning system for Inner-Suspended gin poles

The pressure of the inner suspension pole body is one of the key control indicators that need to be focused on in the design and use of the pole. A real-time intelligent monitoring and early warning system for the working status of the internal suspension pole tower is developed to address safety issues such as excessive inclination, excessive force on the stay wire or support rope during the construction process, including pole body pressure monitoring. The system monitors the axial pressure and inclination angle of the pole body using an integrated sensor for the axial pressure and inclination angle of the pole body. The tension sensor monitors the tension of the lifting, pulling, and supporting ropes, and the anemometer monitors the environmental wind speed. The monitoring data is fed back to the monitoring system through a wireless transmission module, and the safety of the pole state is determined in real-time through an embedded algorithm. When the preset threshold is exceeded, an audible and visual warning is issued. A comparison was made between the actual lifting test and theoretical calculation values, and engineering applications were completed.

A novel fiber‐reinforced polymer rope: Simulation and theoretical investigation

AbstractThe study proposed using twisted rope made of flexible fiber‐reinforced polymers (FRPs) instead of wire and synthetic ropes in high load‐bearing and corrosive environments. Finite element model verification and parameter analysis were conducted for the rope, along with deriving theoretical equations for its tensile properties. Increasing the lay length improved model accuracy, with a maximum bearing capacity within a 10% margin of error compared to experimental results. The model length had minimal impact on calculation results, while changes in radial mesh size (0.13 and 0.2 mm) and friction coefficient (0–0.2) greatly affected maximum contact stress. The tensile strength and elastic modulus of the strand remained almost constant (approximately 1142 MPa and 44 GPa) when the friction coefficient was altered. Increasing lay length (6D–20D) enhanced the tensile properties of the strand, whereas tendon diameter (1–3 mm) had negligible impact. Arranging inner and outer strands with the same lay length was better for circular ropes than those with the same lay angle. Inverse lay direction reduced rope torque and increased strand contact stress. Rectangular ropes had higher strength and modulus conversion efficiency, with lower contact stress compared to circular ones. The accuracy of rope equations improved with longer lay lengths, and adding a correction factor for lay length can modify the equation.Highlights A flexible FRP rope with high strength and twisted form was proposed. The effect of construction factors on the tensile behaviors of ropes was clarified. Equations for calculating the tensile properties of ropes were derived.

Modeling and Numerical Computation of the Longitudinal Non-Linear Dynamics of High-Speed Elevators

High-speed elevator systems comprise numerous components, and vibration issues are prevalent. The evident non-linear behavior resulting from changes in the wire rope length adds complexity to the investigation of elevator dynamics issues. This paper investigates dynamics modeling and numerical solution methods for longitudinal vibrations in a typical high-speed elevator system. The primary contributions of this paper include constructing a dynamics model for high-speed elevators using a substructure dynamics modeling approach. This model incorporates Newton’s law and the Lagrange equation to comprehensively represent the dynamics of the elevator car, car frame, traction system, and tension system. Additionally, a non-linear dynamics model of the steel wire rope is developed using the centralized mass method. This paper also presents an algorithm to solve the time-domain dynamics based on the variable-step-length Runge–Kutta method. Furthermore, it investigates the non-linear dynamics of elevators considering variations in the elevator’s intrinsic frequency and different elevator control strategies, focusing on the response characteristics of high-speed elevator dynamics. The findings of this thesis hold significant importance in the field of high-speed elevator dynamics. They aid in the design and debugging of high-speed elevator systems and serve as a foundation for future research into the non-linear aspects of elevators.

Cumulative fretting fatigue damage model for steel wire ropes

AbstractFretting fatigue contributes significantly to the fatigue failure process in steel wire ropes at the wire‐to‐wire trellis contact region with partial slip conditions. In this respect, this work demonstrates a new damage‐based fretting fatigue model for the prediction of such a failure process. The model is based on Lemaitre's damage equations for quasi‐brittle material with a damageable micro‐inclusion embedded in an elastic meso‐element. It incorporates the cyclic degradation of the elastic modulus of the drawn steel wire material. The fatigue life model acknowledges the mean stress effect. The constitutive and damage equations are formulated into user material (UMAT) subroutine for integration with Abaqus finite element analysis code. The localized fretting fatigue damage mechanism is simulated with an isolated two‐wire model. The effect of the contact condition with the coefficient of friction of 0.2 and 0.8 on the contact mechanics of the drawn wires is considered. The fretting fatigue mechanism map is established for each simulation case. The simulated results of N0 (no of cycles to initiate damage) and damage variable, D, confirm the fretting fatigue condition as the damage occurs in the slip region of the contact area for both the frictional conditions. The results were found in agreement with the previously establish Ruiz fretting parameter. This study will provide a base for the onward reliability assessment of steel wire ropes.

Nonlinear vibration control of composite beam under base excitation via NiTiNOL–steel wire ropes: experimental and theoretical investigation

Nonlinear vibration control of composite beam under base excitation via NiTiNOL–steel wire ropes: experimental and theoretical investigation

Revision surgery for periprosthetic fracture of distal femur after endoprosthetic replacement of knee joint following resection of osteosarcoma.

Periprosthetic fracture (PPF) is one of the severe complications in patients with osteosarcoma and carries the risk of limb loss. This study describes the characteristics, treatment strategies, and outcomes of this complication. Patients were consecutively included who were treated at our institution between 2016 and 2020 with a PPF of distal femur. The treatment strategies included two types: 1) open reduction and internal fixation with plates and screws and 2) replacement with long-stem endoprosthesis and reinforcement with wire rope if necessary. A total of 11 patients (mean age 12.2 years (9-14)) were included, and the mean follow-up period was 36.5 (21-54) months. Most fractures were caused by direct or indirect trauma (n = 8), and others (n = 3) underwent PPF without obvious cause. The first type of treatment was performed on four patients, and the second type was performed on seven patients. The mean Musculoskeletal Tumor Society (MSTS) score was 20 (17-23). All patients recovered from the complication, and limb preservation could be achieved. PPF is a big challenge for musculoskeletal oncologists, particularly in younger patients. Additionally, PPF poses a challenge for orthopedic surgeons, as limb preservation should be an important goal. Hence, internal fixation with plates and endoprosthetic replacement are optional treatment strategies based on fracture type and patient needs.

Research on the linear driving characteristics of endoscopic continuous robot

Due to the way line drive, the continuous endoscope robot will have a certain lag in the process of movement, which will affect the accuracy and flexibility of the operation. In addition, the hysteresis and return difference caused by wire rope transmission will also increase the hysteresis effect of continuous robots. In this paper, the motion characteristics of the continuous endoscopic robot are analyzed, the hysteresis of the robot is modeled theoretically based on the Preisach model, and the effectiveness of the model is verified. Preisach hysteretic nonlinear hyperbola model predicts the bending changes under different positive and negative drives. The experimental results show that the maximum error between the model and the theoretical prediction is 3.18 degrees. The hysteresis model can predict the hysteresis characteristics of the continuous endoscope robot well.

Mechanical properties of elevator ropes and belts exposed to corrosion and elevated temperatures

Abstract Safety in elevators is extremely important phenomenon. Elevator accidents occurring today are at a level that seriously threatens the safety of life and property, and especially elevator ropes and belts have a very important place in these systems in order not to endanger human life. As with every mechanism, stress, fatigue and deformations occur in elevator parts and equipments such as ropes and belts over time causing impairment and reduce their strength. In this study, artificial defects were given to the 8 × 19 Warrington steel wire rope and polyurethane coated elevator belt to examine the effects of different type of corrosion and elevated temperature deterioration on mechanical properties and their comparisons were made. Results indicate that the percent reduction in lifting capacity of the elevator belt investigated was lower than that of the 8 × 19 Warrington rope in all degradation types examined.

Anchorage capacity of looped wire ropes for connections between precast concrete wall-elements

U-bar loop connections have traditionally been used to establish structural continuity between wall-elements in precast concrete buildings. However, recent advancements have introduced the looped wire rope connection as a viable alternative due to its installation benefits. While the strength of the connection itself has been investigated thoroughly, the anchoring of the looped wire ropes inside the wall-element remains under-investigated.This paper presents an experimental study including 66 experiments focusing on the anchorage and associated failure mechanisms of looped wire ropes. The experimental study investigates various design parameters such as the embedment length of the looped wire rope, the u-bar in the concrete element, concrete compressive strength, the comparison between an embedded bolt and looped wire rope, and the size of the test specimen, which represents the distance between wire ropes in a wall element and the wall thickness.On the basis of the experimental evidence, a mechanical model is developed based on the principles of rigid plastic modelling. This model key design parameters into account and provides an understanding of the anchorage of looped wire ropes. The model, backed by a detailed analysis of failure mechanisms using digital image correlation, provides an improvement in predicting the anchorage capacity of looped wire ropes in concrete wall elements.

Wavelet structuring element-based morphological filtering method in wire rope inspection signal denoising

Aiming at the multi-source interference signals in wire rope inspection, while common morphological filtering methods with traditional structuring elements are hard to distinguish, a new wavelet structuring element-based one-dimensional (1D) generalized morphological filtering method is proposed. First, principles and related theories of the generalized morphological filter are introduced and then the new wavelet structuring elements are analyzed. Thereafter, simulation and comparison regarding common structuring element morphological filter and the new wavelet function-based models are conducted through signal-to-noise ratio (SNR) and mean square error (MSE) analysis. Meanwhile, the influence of different noises and main structuring element parameters of length L, amplitude H to the signal processing results are revealed. Finally, experiments for different wire rope defects inspection by magnetic flux leakage testing are conducted, and characterizations of the wavelet structuring element-based morphological filtering methods are presented and compared through six case studies. Besides, the superior performance of the wavelet structuring morphological gradient models are compared and validated by short-time Fourier transform, SNR, MSE analysis, and quantitative defect recognition. The comparison results show that db4 and sym4 wavelet structuring elements-based 1D morphological filter features the highest wire rope defect detection and signal recognition accuracy under the gradient operation, which demonstrates the feasibility and effectiveness of the proposed methods. Additionally, advantages and disadvantages of the new models are summarized and discussed.

Experimental and numerical study on the shock characteristics of an electric switchboard with wire rope isolators in naval ships

Naval vessels face significant challenges owing to vibrations and shocks originating from diverse sources. Maintaining high levels of vibration and shock resistance in ship equipment is crucial to prevent damage and ensure proper functionality in demanding environments. This study experimentally and numerically investigates the shock characteristics of an electric switchboard on a naval ship using wire rope isolators (WRIs). Following the MIL-S-901D standard, impact tests were conducted using a test model. A simplified WRI model was constructed based on a previous study using the finite element method. The tests were performed in the vertical and 30° inclined orientations, and the experimental and simulation results were compared. Although an overall agreement was observed between the two, some inconsistencies were noted. These discrepancies were attributed to the inaccurate representation of the WRI. The dynamic stiffness of the WRI derived from the vibration tests conducted in this study may not be suitable for impact tests. Additionally, the modelled WRI in the simulation, as a 1D spring element with different support points, differed from the experimental setup, possibly causing localized effects that influenced the stress distribution. This study emphasizes the importance of refined WRI modelling for accurate shock simulations and offers insights into enhancing the shock resistance of naval ship equipment.

Design and Improvement of the Connection Between the Steel Wire Rope and Shell for Cobalt-60 Afterloading Source Whip

This article studied a novel connection method between the steel wire rope and the outer shell of a cobalt-60 afterloading brachytherapy source delivery whip. The performance requirements for the connection between the steel wire rope and the shell are described by analyzing the structural characteristics and usage environment of the source whip. Multiple joint forms and process ideas are proposed and explored. After repeated testing and improvement, a set of embedded adhesive bonding connection methods is finally proposed. The small-diameter cobalt-60 afterloading radiation source whip produced by this method meets the requirements of experimental verification and clinical use, effectively solving the problem of connection between the radiation source shell and steel wire rope.

Quantitative Study on Cross Section Damage of Steel Wire Rope Based on Magnetic Signal Characteristics Under Weak Magnetic Excitation

Quantitative Study on Cross Section Damage of Steel Wire Rope Based on Magnetic Signal Characteristics Under Weak Magnetic Excitation

Fatigue strength of synthetic rope: experimental methodology

Crane industries and industrial lifting companies aims to reduce the overall weight of the winch and limit the systematic use of steel wire rope in order to increase their competitiveness. This overall weight reduction can result from the lightering of the rope using synthetic material. Metallic rope fatigue behaviors are well documented and criteria for maintenance are established in the ISO 4309 standard unlike non-metallic ropes fatigue behaviors. Many unknowns remain, as failure modes, fatigue strength, ratting criteria, tribological behavior and friction, etc...In this context, CETIM and its industrial partners have launched, within a working group, a research program to evaluate the fatigue performance of synthetic ropes subjected to periodic bending stress. A specific scale 1:1 test bench which simulates the winding of the rope around the pulleys and drums was developed and Fatigue tests was performed on synthetic ropes. This test bench can be used on several rope geometries and dimensions, material (aramid, HMPE…), and loadings.This paper presents the test bench and discusses the experimental methodology developed to test synthetic ropes in fatigue bending mode.

Improved Reconstruction of Magnetic Flux Leakage Signal From Wire Rope Damage Using Novel Smooth Function and Feature Peak Compensation

Improved Reconstruction of Magnetic Flux Leakage Signal From Wire Rope Damage Using Novel Smooth Function and Feature Peak Compensation