Distribution of wire deformation within strands of wire ropes

Using ANSYS software, we developed a modeling program for several kinds of wire ropes with metal cores and built a geometric model for the 6×19 IWS wire rope. Through proper grid partitioning, a finite element model for calculating the deforma-tion of wire rope was obtained. Completely constraining one end of the wire rope and applying an axial force to the other end, we established the boundary conditions for solving the model. In addition, we numerically simulated the stress and deformation of the wire, obtaining the deformation distribution of each wire within the wire rope under different laying directions. At the end, a tensile test of the 6×19 IWS wire rope was carried out and the results of simulation and experiment compared.

Design and Modeling on Stranded Wires Helical Springs

A stranded wires helical spring is formed of a multilayer and coaxial strand of several wires twisted together with the same direction of spiral. Compared with the conventional single wire spring, the stranded wires helical spring has the notable predominance in strength, damping and vibration reduction, which is usually used in aircraft engines, automatic weapons, etc. However, due to its complicated structure, the precise computation of its strength and rigidity need be a correct mathematical model, which then will be imported to finite element analysis software for solutions. Equations on solving geometric parameters, such as external diameters of strands and screw pitches of wires, are put forward in the paper. It also proposes a novel methodology on solving geometric parameters and establishing entity models of the stranded wires helical spring, which provides foundation of computing mechanical parameters by FEA. Then mathematical models on the centre line of the strand and the surface curve of each wire, after closing two ends in a spring, are proposed. Finally, geometric parameters are solved in a case study, and a 3D entity model of a spring with 3 layers and 16 wires is established, which has validated the accuracy of the proposed methodology and the 3D entity mathematical model. The method provides a new way to design stranded wire helical spring.

Dynamic design of a nonlinear energy sink with NiTiNOL-steel wire ropes based on nonlinear output frequency response functions

A novel vibration isolation device called the nonlinear energy sink(NES)with NiTiNOL-steel wire ropes(NiTi-ST)is applied to a whole-spacecraft system.The NiTi-ST is used to describe the damping of the NES,which is coupled with the modified Bouc-Wen model of hysteresis.The NES with NiTi-ST vibration reduction principle uses the irreversibility of targeted energy transfer(TET)to concentrate the energy locally on the nonlinear oscillator,and then dissipates it through damping in the NES with NiTi-ST.The generalized vibration transmissibility,obtained by the root mean square treatment of the harmonic response of the nonlinear output frequency response functions(NOFRFs),is first used as the evaluation index to analyze the whole-spacecraft system in the future.An optimization analysis of the impact of system responses is performed using different parameters of NES with NiTi-ST based on the transmissibility of NOFRFs.Finally,the effects of vibration suppression by varying the parameters of NiTi-ST are analyzed from the perspective of energy absorption.The results indicate that NES with NiTi-ST can reduce excessive vibration of the whole-spacecraft system,without changing its natural frequency.Moreover,the NES with NiTi-ST can be directly used in practical engineering applications.

Three-stage Method for Identifying the Dynamic Model Parameters of Stranded Wire Helical Springs

The dynamic behavior of the stranded wire helical spring is described by a modified Bouc-Wen model while the model parameters must be identified using an identification method and experimental data. Existing identification methods usually relies either solely nonlinear iterative algorithms or manually trial and error. Therefore, the identification process can be rather time consuming and effort taking. As a result, these methods are not ideal for engineering applications. To come up with a more practical method, a three-stage identification method is proposed. Periodic loading and identification simulations are carried out to verify the effectiveness of the proposed method. Noises are added to the simulated data to test the performance of the proposed method when dealing with noise contaminated data. The simulation results indicate that the proposed method is able to give satisfying results when the noise levels are set to be 0.01, 0.03, 0.05 and 0.07. In addition, the proposed method is also applied to experimental data and compared with an existing method. The experimental data is acquired through a periodic loading test. The experiment results suggest that the proposed method features better accuracy compared with the existing method. An effective approach is proposed for identifying the model parameters of the stranded wire helical spring.

Dynamic behavior of bridge-erecting machine subjected to moving mass suspended by wire ropes

The dynamic behavior of a bridge-erecting machine, carrying a moving mass suspended by a wire rope, is investigated. The bridge-erecting machine is modelled by a simply supported uniform beam, and a massless equivalent ＂spring-damper＂ system with an effective spring constant and an effective damping coefficient is used to model the moving mass suspended by the wire rope. The suddenly applied load is represented by a unitary Dirac Delta function. With the expansion method, a simple closed-form solution for the equation of motion with the replaced spring-damper-mass system is formulated. The characters of the rope are included in the derivation of the differential equation of motion for the system. The numerical examples show that the effects of the damping coefficient and the spring constant of the rope on the deflection have significant variations with the loading frequency. The effects of the damping coefficient and the spring constant under different beam lengths are also examined. The obtained results validate the presented approach, and provide significant references in the design process of bridgeerecting machines.

Effect of Tension on Friction Coefficient Between Lining and Wire Rope with Low Speed Sliding

In order to obtain the exact friction coefficient between lining and wire rope, the tension of wire rope is studied as a factor which affects this coefficient. A mechanical model of a wire rope subjected to axial load was established to determine the torque of the wire rope. The contact motion between lining and wire rope was regarded as a screw rotation and the axial force of the lining resulting from the torque of the wire rope was analyzed. Theoretical formulas relating tension of the wire rope and the friction coefficient was obtained. Experiments between lining and wire rope with low sliding speed were carried out with friction tester made by us. Experimental results show that increment of the friction coefficient is proportional to that of the tension of the wire rope with a low sliding speed. The experimental results agree with the theoretical calculation; the errors are less than 6%, which oroves the validity of the theoretical model.

Numerical investigation of the seismic response of a UHV composite bypass switch retrofitted with wire rope isolators

An ultra-high voltage(UHV)composite bypass switch(BPS)faces increasing seismic challenges when UHV projects extend to high seismic intensity areas.The UHV composite BPS still generates excessive stress at the bottom section although hollow composite insulators with high flexural strength are adopted.Since the standard retrofitting strategy by using stiffer supports cannot reduce stress responses,wire rope isolation is introduced.The optimal design of isolation considers both stress and displacement responses since the slenderness and composite material of insulators contribute to significant displacement.The results show that properly designed isolation can significantly reduce stress without excessive displacement responses.A larger radius configuration helps to improve the applicability of small stiffness isolators under high winds.When the isolation still cannot satisfy the requirement,smaller stiffness isolators with a larger radius,or isolators with increased loops and smaller radius,can be introduced to gain better energy dissipation capacity and effectiveness in response mitigation.Accordingly,a three-step design procedure is proposed to increase the damping force but fix the rotational stiffness of isolation.Hence,the application of wire rope isolation can be extended to UHV composite BPS with a low natural frequency,but conductors with enough redundancy should be used.

Key technique of a detection sensor for coal mine wire ropes

Wire ropes,employed extensively in coal mine hoists and transportation systems are subject to damage due to wear,corrosion and fatigue.The extent of damage and the carrying capacity of ropes are closely related to the sense of safety by staff and equipments.Magnetic flux leakage detection method(MFL),as an effective method,is these days widely used in detection of broken strands of wire ropes.In order to improve the accuracy of detection of flaws in wire ropes by magnetic flux leakage(MFL),the effect of the distance between a sensor and the surface of a wire rope(i.e.,lift-off) on detection by magnetic flux leakage was in-vestigated.An analysis of the main principles for the choice of lift-off is described by us and a new method that improves the structure of the detector is proposed from the point of view of the design of a magnetic circuit,to restrain the impact of fluctuations of sensor lift-off.The effect of this kind of method is validated by simulation and computation.The results show that the detection sensitivity is markedly increased by this method.Furthermore,the signal-to-noise ratio(SNR) can be increased by over 28%.This method will lend itself to offer reliable scientific information to optimize the structure of excitation devices and improve the accuracy of MFL detection.

A novel finite element model for single-layered wire strand

A new finite element model for single-layered strand was investigated for accurate and efficient mechanical behavior analysis.Mathematical model was created by sectional path-nodes sweeping and dynamic node-beam mapping.Geometric relations between nodes in center core wire and helical wires were deduced in tension and bending incorporating material elasticity theory and deformation geometrical compatibility.Based on Timoshenko beam theory,strand of a pitch length was modeled with specific material,geometric parameters and synthesized constraint equations defined in ANSYS software,and predetermined load cases were performed.The obtained results show that discrepancies between suggested method and Costello theory do not exceed 1.51% in tension and 6.21% in bending,which verifies the correctness and accuracy of the suggested finite element model in predicting mechanical behavior of single-layered wire strand.

Stress Analysis of Wire Strands by Mesoscale Mechanics

Steel wire ropes have wide application in a variety of engineering fields such as ocean engineering and civil engineering.The stress calculation for steel wire ropes is of crucial importance when conducting strength and fatigue analyses.In this study,we performed a finite element analysis of single-strand steel wire ropes.For the geometric modeling,we used an analytic geometry of space method.We established helical line equations and used the coordinates of the contact points.The finite-element model was simplified using the periodic law.Periodic boundary conditions were used to simulate a wire strand of infinite length under tensile strain,for which we calculated the cross-sectional stresses and inner forces.The results showed that bending and torsion moments emerged when the wire strand was under tensile load.In some cases,the bending stress reached 18%of the tensile stress,and the torsion stress reached 29%of the tensile stress,which means that the total stress was higher than the nominal stress.Whereas in ear-lier studies,a conservative prediction of nominal stress was not possible,the results of our strength and fatigue analyses were more conservative.

Computation of the Strand Resistance Using the Core Wire Strain Measurement

This paper proposes a method enabling to compute the prestressing strand resistance using the strain measured on only one core wire. Numerical analysis is conducted considering the pitch length of the strand and the diameters of the core wire and helical wires as parameters. The results verify that the relation between the stresses of the core wire and helical wires can be expressed in terms of the helical angle. Based on this observation, a formula computing directly the prestress force in the strand from the strain measured in the core wire is suggested. Owing to the recently developed measurement method for the core wire strain, the proposed formula can be exploited to determine the prestress of the strand.

Principles of X-Ray Non-Destructive Testing for Steel Wire Ropes in Conveyer Belt

The principles of X-ray Non-destructive testing (NDT) for steel wire ropes buried in conveyer belt is described in the paper. The mathematical model for calculating the effective cross section of wire ropes has been developed. The test data on steel wire rope samples of various types are presented,which have been compared with the National Standard. And this calculation model for the effective cross section is very important to the prediction system for transverse failure of conveyer belt.

Investigation into Failure in Mining Wire Ropes—Effect of Crystallinity

A range of blends of polypropylene-polyethylene are investigated for their mechanical performances. These speciality polymer blends are chemically designed to suit high modulus/high load bearing mining wire rope applications subjected to continued bending and tensile stresses and fluctuating loads and are exposed to extreme weather conditions. In this paper we study the influence of different parameters on the performance of the wire ropes: chemistry of polymer, crystallinity of the polymer matrix, and the morphology. The FTIR and SEM studies revealed that the high fraction of polypropylene in polypropylene-polyethylene matrix lead to early failure as a result of incompatibility and phase segregation and high spherulite sizes of the polymer matrix.

A Methodology for Identifying Defects in Wire Rope Based on Permanent Magnet Excitation

A wire rope defects detection method based on permanent magnet excitation is proposed.A detection system,mainly composed of permanent magnet excitation,distance detection,multi-sensor magnetic flux leakage signal acquisition and data analysis device,is set up.According to the different characteristics of the multi-sensor magnetic flux leakage signal,the localized fault(LF)and loss of metallic cross-sectional area(LMA)signal is separated,and then the two defects can be detected.The experiments show that the method can effectively detect the two defects when they appear simultaneously on the wire rope.

Two-Dimensional Numerical Simulation of Flow Around Three-Stranded Rope

Three-stranded rope is widely used in fishing gear and mooring system. Results of numerical simulation are presented for flow around a three-stranded rope in uniform flow. The simulation was carried out to study the hydrodynamic characteristics of pressure and velocity fields of steady incompressible laminar and turbulent wakes behind a three-stranded rope. A three-cylinder configuration and single circular cylinder configuration are used to model the three-stranded rope in the two-dimensional simulation. The governing equations, Navier-Stokes equations, are solved by using two-dimensional finite volume method. The turbulence flow is simulated using Standard κ-ε model and Shear-Stress Transport κ-ω(SST) model. The drag of the three-cylinder model and single cylinder model is calculated for different Reynolds numbers by using control volume analysis method. The pressure coefficient is also calculated for the turbulent model and laminar model based on the control surface method. From the comparison of the drag coefficient and the pressure of the single cylinder and three-cylinder models, it is found that the drag coefficients of the three-cylinder model are generally 1.3–1.5 times those of the single circular cylinder for different Reynolds numbers. Comparing the numerical results with water tank test data, the results of the three-cylinder model are closer to the experiment results than the single cylinder model results.

矿用钢丝绳捻向攀爬轮式巡检机器人设计

针对矿用钢丝绳无人巡检需求,设计研制了一种沿钢丝绳捻向攀爬的巡检机器人。该机器人所需的驱动力约为传统沿轴向攀爬机器人的0.915倍,携带负载3 kg时,其越障高度比轴向攀爬机器人的越障高度大0.6 mm,障碍物高度为3 mm时,它携带的最大负载比轴向攀爬机器人大0.4 kg。模拟深井环境开展了钢丝绳振动工况下的巡检机器人攀爬实验。研究结果表明:在钢丝绳静止状态下,攀爬机器人展现出稳定的攀爬性能,最大攀爬速度达到8.25 m/min,可连续攀爬500 m;在低频大幅振动工况下,机器人攀爬速度高于静止时的速度;在高频小幅振动工况下,钢丝绳振动会导致攀爬速度小幅度波动。

基于整体与局部纹理特征加权融合的港机装备钢丝绳断丝缺陷检测研究

钢丝绳是港机装备的重要部件,由于作业工况环境恶劣,钢丝绳表面极易引起断丝等缺陷,影响港机装备作业安全。针对港机装备钢丝绳表面油泥严重、光照亮度不均,以及港机装备钢丝绳断丝缺陷能够在钢丝绳股顶钢丝椭圆形区域内有效体现的特点,提出了一种基于钢丝绳整体纹理特征与股顶钢丝椭圆形区域边缘轮廓纹理特征加权融合的钢丝绳断丝缺陷检测方法。首先采用图像降噪、增强、校正技术对钢丝绳原始图像进行预处理。然后采用图像平滑、阈值分割及边缘特征提取技术对股顶钢丝椭圆形区域边缘轮廓进行提取。接着采用局部二值模式(LBP)算子分别提取钢丝绳整体纹理特征与股顶钢丝椭圆形区域边缘轮廓纹理特征,并对钢丝绳整体纹理及边缘轮廓纹理特征进行特征加权融合。最后对加权融合后的特征向量进行主成分分析(PCA)法降维,并应用支持向量机(SVM)技术对钢丝绳断丝缺陷进行检测。研究结果表明:本文提出的方法对实际工况下重油泥、光照不均等钢丝绳断丝缺陷具有较好的检测效果,具有一定的工程应用价值。

卫星运输T型钢丝绳隔振器刚度及阻尼研究

钢丝绳隔振器可以缓解卫星运输过程中振动产生的危害,但其缺少试验基础研究,无法提供仿真输入,难以准确实现卫星损伤仿真。针对此问题,对T型钢丝绳隔振器刚度及阻尼特性进行了理论分析和试验研究。首先,对钢丝绳隔振器系统的力学特性进行了理论分析,建立了理想的迟滞回环曲线;其次,建立了钢丝绳隔振器静刚度和动刚度力学测试系统;最后,通过准静态加载以构建静刚度条件下压缩、横滚、剪切状态力和位移的关系。在预承载力为5 kN、振幅为1 mm条件下,分别测试了激振频率5~8 Hz条件下的动刚度性能。结果表明:准静态加载条件下,钢丝绳隔振器的力和位移关系较为稳定;动刚度条件下,在5~8 Hz频率之间,动刚度变化较为稳定;等效阻尼随着激振频率的增加而增加。

球型钢丝绳隔振器非对称迟滞模型

针对球型钢丝绳隔振器的非线性刚度和阻尼特性导致迟滞模型表征困难的问题,提出了非线性弹性因子和修正因子改进的归一化Bouc-Wen迟滞模型,结合Simulink仿真完善改进的迟滞模型,采用最小二乘法和遗传算法相结合的方法对改进模型进行参数识别。通过数值仿真绘制GGQ25-62L型球型钢丝绳隔振器在不同工况的迟滞环,并和实验数据进行对比。结果表明,参数识别方法准确可靠,实验数据和理论计算曲线具有较强的一致性,该模型能够有效地描述隔振器的动态特性。

6×19S钢丝绳的断裂有限元模拟

应用微分几何方法建立了钢丝绳一阶和二阶空间螺旋线的方程表达式,构建了6×19S钢丝绳的几何参数模型。对参与捻制的各规格钢丝进行了力学拉伸测试,构建了钢丝绳的弹塑性本构模型,通过缺口拉伸试验结合有限元方法拟合了Johnson-Cook断裂准则的相关参数,获得了拟合参数值,利用ABAQUS模拟了钢丝绳承受轴向载荷后弹性-塑性-断裂的完整过程,探讨了钢丝绳过度加载时的断丝规律以及温升变化规律,结果表明,各股外层丝受到挤压和磨损,承受了更大的接触法向力,最先发生断裂,其次是主股外层细丝难以承受较大拉力开始大规模断裂,最终导致主股粗丝与芯股迅速发生断裂,钢丝绳的接触磨损与过载断裂会带来明显的温度变化,大部分区域的温升在15~30℃。