Wire Rope Tension Research Articles

A semi-analytical method of passive heave compensator for the splash zone crossing: Modeling and application

The splash zone crossing poses the major challenges during offshore payload handling, making the Passive Heave Compensator (PHC) crucial. However, limited quantitative research exists on the crossing behaviors, such as sling slack and snap load. This study introduces a semi-analytical model considering slamming load and wire rope tension, within the potential flow theory and vibration theory. A novel contribution is the detailed description of the compensator's parameter optimization method for the splash zone crossing, demonstrated through an example application. Nonlinear stiffness parameters significantly affect the slamming load's handling capacity of the compensator, reflecting marked difference in rope tension response. The proposed method enables the feasible region of PHC's stiffness parameters for the splash zone crossing to be found. Simulation results employing the parameters within the feasible region show that the tension was reduced by approximately 72% (crane end) and 89% (load end) during crossing compared to without PHC, and slamming impulse is reduced by about 45%. This paper constitutes an efficient PHC design method for splash zone crossing in engineering applications.

EXPERIMENTAL STUDYING A POSSIBILITY OF CLOSE-COUPLED TOWING OF LARGE-SIZED VESSELS BY ICEBREAKER

The experimental studies in the ice model tank of the Krylov State Research Centre are described in the paper. This study aimed at researching a possibility of close-coupled towing of large-sized vessels by icebreaker. The displacement of considered commercial vessels is several times greater than the icebreaker displacement. Due to the fact that an amount of cargo transported along the Northern Sea Route is growing every year and new terminals are being constructed for the export of raw materials extracted in the Arctic, it has been shown in the paper that new transport vessels with high cargo capacity should be designed and built for the efficient operation of terminal. It has also been shown that the organization of independent year-round operation of such vessels in the Arctic region is extremely difficult, therefore, even at the stage of their design it’s important to consider the possibility of their escorting by existing icebreakers. The feasibility of close-coupled towing in the escorting of large-sized vessels with low ice class by icebreakers in the Arctic waters has been studied in the paper. The models of the greatest existing nuclear-powered icebreaker and conditional bulk carrier are used as an object of the ice model tests. The study of the close-coupled towing features in the continuous flat ice conditions is carried out at straightforward movement and gyration, as well as for the case of an emergency stop of the icebreaker. During ice model tests the ice forces acting on the hull of the model are measured, as well as the load on a towing notch with rubber fenders in the stern of icebreaker and the tension in the wire rope. The comparison of the wire rope tension with its breaking force is taken as a criterion to assess the possibility of the close-coupled towing operation. The results can be used as the basis for choosing the hull concept of the future large-sized vessels, its ice class and main dimensions and in strategic simulations of Arctic marine transport systems.

Multi-Disturbance Observers-Based Nonlinear Control Scheme for Wire Rope Tension Control of Hoisting Systems with Backstepping

The objective of this paper is to pursue a wire rope control methodology for reducing the tension difference between two wire ropes of a hoisting system. As we know, complicated disturbances exist in the complex electro-hydraulic hoisting system, notably, some of these disturbances are coupled, such as high-speed airflow disturbances, structure vibrations and vibrations in flexible wire ropes. Furthermore, there are model errors in force modeling due to the Coulomb friction between two wire ropes and two moveable head sheaves in the real physical hoisting systems. To eliminate disturbances, two types of disturbance observers (DOs) are employed: a traditional disturbance observer (TDO) and a coupled disturbance observer (CDO), both of which are utilized to estimate and compensate for the Coulomb friction and coupled disturbances online. As a result, a nonlinear backstepping control scheme is presented with estimation values from the TDO and the CDO. The experiment’s results demonstrate the effectiveness of the proposed control methodology.

An Adaptive Dynamic Surface Technology-Based Electromechanical Actuator Fault-Tolerant Scheme for Blair Mine Hoist Wire Rope Tension Control System

As an important equipment for deep well hoisting, the safe and stable operation of the Blair mine hoist is vital for the development and utilization of deep mineral resources. However, it is always a challenging task to keep consistent wire rope tension in the event of an actuator fault. In this study, an adaptive dynamic surface technology-based actuator fault-tolerant scheme is proposed. A fault observer with a neural network adaptation term is designed to estimate the loss of actuator efficiency caused by faults. Considering the redundant characteristic of the two actuators, a novel dynamic surface technology-based controller with a fuzzy assignment and state constraints is developed to eliminate the impact of fault. The stability of the closed-loop system under the proposed strategy is theoretically proved by rigorous Lyapunov analysis. Comparative experiments under various conditions are carried out on a xPC based mine hoist platform, and the results show the applicability together with the superiority of the proposed scheme.

Control and Dynamic Simulation of Wire-Driven Precise Spray Robotic Arm

The spraying of citrus to kill insects is a necessary part of the citrus planting process. Most of the currently used sprayers are cover sprays, which cannot achieve accurate and low-consumption spraying. Causing a lot of pesticide waste and environmental pollution. Aiming at the difficulty of precise spraying of citrus leaves, this paper proposes a soft spraying manipulator with good bending characteristics and flexible operation ability. The robotic arm consists of 6 joints and 2 arm segments. The two arm segments of the robotic arm are driven by two wire ropes and move in two orthogonal planes respectively. The PD controller design is designed. The joint state observers are constructed to predict joint angles, angular velocities, and other information. The dynamic simulation experiment is carried out, and the relationship between the wire rope tension and the spring elastic force changes with time, and the relationship between each joint angle changes with time. These make the wire-driven precise spray robotic arm potentially useful in agricultural spraying.

Study on Damage Tests Based on Structure and Operating Parameters of Wire Ropes Used by Conveyors in Orchards

Abstract The regularity of wire rope breakage of new-type rail conveyors used in orchards is not clear yet. The breakage may be mainly associated with the diameter and material of pulleys, wire rope tension, and linear speed, as well as exposure to acid rain and sandy soil. This paper took wire rope structure and operating parameters as the research object, designed and built a simulation conveyor wire rope winding test platform based on programmable logic controller (PLC), and verified the feasibility of the system to automatically control wire rope tension, and then conducted the wire rope winding test. According to the tests, a wire rope will have earlier wire breakage and faster wear if it works at a higher speed or in greater tension—a wire rope reached the scrapping criterion after 2,000 cycles of working at the speed of 29.35 m/s or at the tension of 6,500 N. Sandy soil and acid rain are also great contributors to wire breakage, and finer sandy soil or greater acidity of acid will cause more severe wire breakage—a wire rope reached the scrapping criterion after 3,300 cycles of work if exposed to acid rain with pH value of 2.0. Pulley diameter also counts: the smaller the pulley diameter is, the less wear the pulley will cause; and pulley material also plays a part—Q235 steel pulley may cause greater wear than a nylon pulley. Wear and plastic deformation of outer wires lead to surface material loss of a wire rope, thereby resulting in crack or even fracture of single wires, greater tension of other unbroken wires, and accelerated wear of the whole wire rope to the scrap criterion. The study aims to provide a reference for optimizing the safety performance of conveyors in orchards, as well as for maintenance and care of wire ropes in other applications.

Tension Monitoring and Defect Detection by Magnetostrictive Longitudinal Guided Wave for Fine Wire Rope

Fine wire rope is a type of skeleton material that is used widely in elevator steel belts, conveyor belts, and synchronous belts. When the tension of a fine wire rope changes abnormally, its service life and the safe operation of the system it belongs to will be seriously affected. Therefore, it is particularly important to monitor the tension and detect the defects of fine wire rope. However, traditional nondestructive testing technology only detects the defects or monitors the tension of the tested structure. In this article, longitudinal guided wave sensors are used to measure the tension changes and defects of fine wire rope. When the tension of a fine wire rope changes, the natural frequencies of the fine wire rope change, so the change of natural frequencies of fine wire rope can be used to represent the change of tension. White noise is used to measure the natural frequencies of fine wire rope under varying tension using a low-power circuit to determine the influence of the change of fine wire rope tension on the natural frequencies. Meanwhile, the excitation frequency needed to produce the maximum amplitude of the guided wave is determined according to the natural frequencies detection results to improve the signal-to-noise ratio of the guided wave signal. Additionally, defect detection is realized by analyzing the wave velocity and time of flight of the guided wave signal.

Uncertainty analysis and time-dependent reliability estimation for the main shaft device of a mine hoist

The main shaft device (MSD) is a key component of the mine hoisting system. During lifting, vibration of the system will cause dynamic tension of wire rope at both ends, resulting in the complex stress state at the critical location of the MSD and thus considerably decreasing its service life. This study is aimed at investigating time-dependent reliability of the MSD based on fatigue damage accumulation. Firstly, the actual service-loading history of wire rope during lifting was simulated. Then, the residual strength degradation models of the MSD following different shifts were established based on Palmgren-Miner hypothesis. Furthermore, the performance function of time-dependent reliability considering residual strength degradation was established. Finally, time-dependent reliability of the MSD was evaluated by adopting moment-based saddlepoint approximation. The results show that when the MSD follows a heavy shift, the corresponding reliability drops rapidly with the passage of service time. In addition, a reliable shift of the MSD after gridding was made. According to this shift, the remaining reliable service life of the MSD for multi-shift can be predicted.

A Robust Nonlinear Controller With Low-Gain-State-Observer for Wire Rope Tension Active Control of Hoisting Systems

In this paper, a modified double-rope winding hoisting system (MDWHS) is proposed for ultra-deep mines. Nevertheless, the MDWHS has wire rope tension imbalance issues due to lift inconsistency of two wire ropes. A combined control algorithm is designed for wire rope tension active control considering the nonlinear uncertainties subjected to the MDWHS, where a low gain state observer (LGSO) and a robust nonlinear adaptive controller are employed via backstepping theory. Firstly, to investigate the wire rope tension active control method, the dynamics model of the MDWHS is established. Then, the LGSO is employed to estimate unmeasured system state variables and to optimize perturbed system state variables. Finally, a robust nonlinear control method is employed to acquire prospective control input. The combined control algorithm can ensure the desired transient and final tracking accuracy, which is essential for tracking control of wire rope tension active adjustment. The stability of the overall closed-loop system with the presented control algorithm can be verified referring to the Lyapunov theory. Experimental results conducted on the established double-rope winding hoisting simulation experimental system demonstrate that the proposed active control method exhibit more advantageous performance on wire rope tension balance control compared with the conventional Proportion Integration (PI) and adaptive backstepping controller (ABC).

Research and optimization of intelligent diagnosis algorithm based on rope tension

For less monitor and poor performance in the intelligence of the existing fault diagnosis system based on wire rope tension, an optimized intelligent diagnosis algorithm is proposed to diagnose the faults. These faults are difficult to monitor in the past, such as blocked cage, over-wind and slipped rope. Selecting the radial basis function (RBF) as the kernel function, two parameters of penalty factor and radial basis kernel parameter in the least squares support vector machine (LSSVM) are further optimized by artificial bee colony (ABC) algorithm. The results show that the LSSVM algorithm does not need a large number of original data, and has no overfitting and generalization ability. The prediction accuracy and the mean square error of the ABC-LSSVM algorithm are improved. It shows better pattern recognition performance, which can be used as a kind of intelligent diagnosis algorithm for the design of the rope tension fault diagnosis system.

Research on The Influence of Rope Jumping on The Tension of Multi-layer Winding Wire Ropes in Super Deep Mine Hoisting Machine

Aimed at the process of rope arrangement in double-rope winding drum of super-deep mine hoist, the tension change during rope jumping fault is studied. By analyzing the relationship between the length difference of two ropes caused by rope jumping and tension, the tension simulation model of multi-layer winding drum rope jumping is established in MATLAB, and the results of simulation and experiment are analyzed and compared. The results show that the rope jumping fault will lead to the tension change of the two ropes, and under different rope jumping faults, the tension change law of the rope is different. The simulation model can well reflect the relationship between rope jumping and tension change, and can quantitatively simulate the tension change during rope jumping. These results have important reference value for fault diagnosis research of hoisting system jump in ultra-deep mine.

Study on dynamic characteristics and compensation of wire rope tension based on oil pressure sensor

The oil pressure sensors are installed on the hydraulic connection device to monitor the tension of wire ropes. The change of acceleration during the operation process of hoist causes the tension change of each wire rope. It leads to impact on the cylinder of hydraulic connection device, enlarges the pressure loss, and makes the non-linear friction become more complex which affects the monitoring accuracy. In this article, the mathematical model of hydraulic connection device is established. To analyze the dynamic characteristics of the hydraulic connection system, the model of single hydraulic cylinder and hydraulic connection device is established and simulated by AMESim software. Then, the friction and pressure compensation in the working process of hydraulic connecting device are obtained by LuGre friction model and corresponding formulas of pressure loss. Finally, the monitoring system is designed and real-time compensation test is carried out. The results show that the compensation improves the accuracy of the real-time measurement system of wire rope tension.

Study on Dynamic Monitoring of Wire Rope Tension Based on the Particle Damping Sensor

Real-time monitoring of wire rope tension is of great significance to the safe operation of mine hoist. Due to the longitudinal and lateral coupling vibration of wire ropes during the operation of hoist, there are high frequency components in measured tension signals of wire ropes, which cannot effectively characterize the actual lifting load. To overcome this problem, a particle damping sensor with a vibration dissipation function is designed in this paper. Multilayered steel balls are placed into the cylindrical cavity of the sensor. Damping vibration and energy dissipation will occur when the sensor is subjected to external excitation. Then, to obtain the optimal sensor characteristics, relevant parameters of the particles and the spoke structure are simulated. Finally, the sensor based on the optimized parameters is manufactured and tested in a coal mine. Compared with the general pressure sensor, the particle damping sensor can effectively eliminate the influence of wire ropes vibration on tension measurement and achieve accurate measurement results.

Research on Dynamic Characteristics and Compensation of Wire Rope Tension and Load Measurement Based on Hydraulic Connection Device

During the operation of hoist, the speed and acceleration of each wire rope are inconsistent and the inertia force is changed due to the wear of the friction pad on the drum, which makes an impact on the cylinder of the tension balance hydraulic connection device and aggravates the flow pressure loss. It results in the nonlinear friction force between the piston and cylinder and affects the accuracy of wire rope tension and load measured by an oil pressure sensor which is installed on the tension balance hydraulic connecting device. In this paper, the simulation model of the tension balanced hydraulic connecting device is established by AMESim software, and the hydraulic dynamic response under different pressures, flow rates, and speed of a single hydraulic cylinder and tension balanced hydraulic connecting device is analyzed. The Leuven friction model is used to compensate the pressure loss along the course and local pressure loss and calculate the friction force, where specific parameters are determined by experiments. The real‐time compensation experiment of the tension balance hydraulic connecting device proves that the device effectively improves the accuracy of wire rope tension and load monitoring.

Study on Resistance Loss of Wire Rope over Pulley

There are many factors affecting the resistance loss of wire rope over pulley, such as tension of wire rope, diameter of pulley, envelop angle and so on. In this paper, based on the mechanical model of wire rope over pulley, the bending effect of wire rope is considered. And the non-linear equations of exit tension with entry tension, pulley radius, envelop angle and bending stiffness are constructed. At last, the influence of various factors on resistance coefficient is analysed.

Wire rope tension control of hoisting systems using a robust nonlinear adaptive backstepping control scheme

This paper concerns wire rope tension control of a double-rope winding hoisting system (DRWHS), which consists of a hoisting system employed to realize a transportation function and an electro-hydraulic servo system utilized to adjust wire rope tensions. A dynamic model of the DRWHS is developed in which parameter uncertainties and external disturbances are considered. A comparison between simulation results using the dynamic model and experimental results using a double-rope winding hoisting experimental system is given in order to demonstrate accuracy of the dynamic model. In order to improve the wire rope tension coordination control performance of the DRWHS, a robust nonlinear adaptive backstepping controller (RNABC) combined with a nonlinear disturbance observer (NDO) is proposed. Main features of the proposed combined controller are: (1) using the RNABC to adjust wire rope tensions with consideration of parameter uncertainties, whose parameters are designed online by adaptive laws derived from Lyapunov stability theory to guarantee the control performance and stability of the closed-loop system; and (2) introducing the NDO to deal with uncertain external disturbances. In order to demonstrate feasibility and effectiveness of the proposed controller, experimental studies have been conducted on the DRWHS controlled by an xPC rapid prototyping system. Experimental results verify that the proposed controller exhibits excellent performance on wire rope tension coordination control compared with a conventional proportional-integral (PI) controller and adaptive backstepping controller.

Rocker Arm Force Analysis of Crown-Block Heave Compensation System Based on ADAMS

This paper compares three common installation ways of swing arm and carries out simulation analysis by using Adams software. The research results show that when using intercrossed enwinding wirerope, the swing arm will bear alternating load and the load variation range is huge, load G’ will change obviously and bring great impact on system control precision. When using along enwinding wirerope, the swing arm’s load is slightly bigger than wirerope tension and the load variation range is very small, load G’ will be static and it’s easy to get high control precision. By reducing the length of lower swing arm, increasing the length of upper swing arm and the offset distance, its working condition can be improved when using intercrossed enwinding wirerope.

Mechanical Properties of Steel Wire Rope Under Combination of Stretch and Bending State

This research through the tests of bending property of a certain steel wire rope in the conditions of no tension state and tension state, obtained a correlation between the bending performance and wire rope tension, defined a gain tension coefficient (k) to the bending stiffness of wire rope, then open a way to research steel wire rope, and developed steel wire rope tension measurement method by three points bending.

The Influence to Mine Hoisting SteelWire Rope Tension and Deformation from Velocity and Acceleration

For studying dynamic characteristics of ultra-deep mine hoisting steel wire rope, according to the differential equation of mine hoisting steel wire rope tension and deformation in the lifting process, we establish the corresponding dynamic simulation model using Matlab-Simulink, carry out simulation experiments according to the ultra-deep mine simulated test parameters, change the value of acceleration and velocity in the lifting process, get variation rule of rope tension and deformation in the lifting process, study the influence to tension and deformation and vibration frequency from acceleration and velocity, provide the theoretical basis and data support for optimal hoisting system design.

A novel tension monitoring device of multi-rope friction hoister by using acoustic filtering sensor

Wire rope tension is one of the vital monitoring parameters for the hoister system, which seriously influence mine coal safety production. However, wire ropes endure vibration and shock in lifting process of multi-rope friction hoisters in coal mine, which interferes with measurement of wire rope tension and lifting load seriously. Aimed to the difficulty of monitoring wire rope tension, this paper put forward a new measurement method of wire rope tension by transferring wire rope tension measurement to pressure measurement, which improves the measurement safety and avoids the safety hazards of adopting pull sensor in series with wire rope, and this paper also designed an acoustic filtering sensor which uses the filtering characteristic of acoustic cavity to eliminate the effect of vibration and shock in wire rope tension measurement. Meanwhile, a novel wire rope tension monitoring device of multi-rope friction hoister is presented based on the proposed measurement method and sensor, which can measure each wire rope tension in the lifting process, display the cage load and monitor the fault of wire rope tension unbalance. Real-time and accurate wire rope tension measurement is realized. By comparing the signals measured by the common sensor and the acoustic filtering sensor, the influence of vibration and shock on the multi-ropes tension measurement is eliminated, and the fault of wire rope tension unbalance can be monitored. This advanced tension monitoring device is of great significance to the safety of coal mine production.