Oh dear, the crane operator, the safety officer at the construction site, and the boss in charge of the equipment, when they see the thick steel wire rope of the crane, do they sometimes feel a jolt in their hearts? This huge device lifts heavy objects up and down every day, exposed to wind, sun and rain. If there are broken wires or breaks hidden inside and they are not discovered in time, it would be a really serious matter! The steel wire rope broke and fell down. The consequences are beyond imagination!
To put it bluntly, a steel wire rope is not a solid iron rod; it is made up of numerous thin steel wires twisted together like a pretzel. The trouble lies right here! Breakpoints don't necessarily occur on the surface where you can see them at a glance. Often, the broken wire breaks inside the "belly" of the rope, or it may seem fine on the surface, but in fact, it has already suffered serious damage inside. Just by looking with the naked eye? Difficult! By the time it really breaks, it will be three springs late.
Don't worry. There are still solutions. There are folk methods and even high-tech ones! Let's say one by one:
Look with your eyes and touch with your hands (the most basic, but don't rely solely on it!)
What to do: Stop regularly and let experienced workers carefully examine the steel wire rope inch by inch and touch it with their hands.
What to look for: Are there any obvious broken threads on the surface that are lifted up? Are there any abnormally swollen or flattened areas? Has the diameter of the rope suddenly become thinner? Are there any particularly sharp or uneven points when touched?
Advantages: No need to spend money on equipment and it can be done at any time.
Disadvantage: It's too demanding on the eyes! It takes too much time! The most crucial point is --Only the superficial injuries can be seen! What's going on inside the rope? Everything went black! Moreover, when people are tired, they tend to make mistakes easily.
Make marks and measure their lengths (a clumsy method, somewhat useful but inefficient)
What to do: On the new rope of the steel wire rope, make a mark with paint at regular intervals (for example, 1 meter).
How to check: Each time you check, measure the length between the two marks with a ruler to see if there is any change (if it has become longer, it indicates that there might be internal wear or broken wires). Or count how many turns the rope has been twisted and see if there are any abnormalities in the number of turns.
Advantage: It is slightly more objective than the naked eye.
Disadvantage: The "internal injury" still cannot be detected! Moreover, as the rope is used for a long time, its surface will wear out, and the marks may disappear and become inaccurate.
Tap it and listen to the sound. (The experience of an experienced master is quite limited.)
What to do: Gently tap the steel wire rope with a small hammer.
What to listen to: Experienced masters can judge by the sound. A clear and continuous sound might be fine. If the sound is muffled or there is a "puff puff" sound, it might be that the inside is loose, rusty or has broken threads.
Advantages: Fast and convenient.
DisadvantageIt all depends on experience! Novices simply can't tell. A noisy construction site is simply impossible to operate. It doesn't work for deep and tiny breakpoints either.
All these old methods mentioned above have a common problem: they are like guessing a melon by its skin! I'm really not sure if it's broken inside. What should I do?
Now it's great. There are high-tech instruments specifically designed to conduct "physical examinations" on steel wire ropes, calledWire rope flaw detector(Also known as non-destructive testing instrument for steel wire ropes). This thing is simply like giving the steel wire rope a "B-ultrasound" and an "X-ray"!
How does the Weite wire rope flaw detector detect "internal injuries"?
Weite has been engaged in the research of wire rope flaw detection for over twenty years and has accumulated rich experience. The principle of their flaw detector is actually quite smart:
Magnetic "scan" the entire body The instrument is like a "big clamp" or a "small wheel", stuck or moving along the steel wire rope. It emits a very strong magnetic field, magnetizing the entire section of the steel wire rope.
Breakpoint "revealed" : Steel wire ropes are made of iron and can conduct magnetism. If there are broken wires, wear and tear, rust and other "injuries" inside, the magnetic field will "leak magnetism" at this place or become different.
The instrument "instantly understands" the alarm The flaw detector is equipped with sensitive sensors that can immediately capture these abnormal magnetic field changes. The instrument screen immediately showed, "What's the problem?" How big is the problem? Was it a broken thread? Did it still break?" It will also sound a "beep beep beep" alarm to remind you! The data is automatically saved to generate a detailed "physical examination report".
There are quite a few benefits to using a micro flaw detector
"Internal wounds have nowhere to hide: Whether the broken wire is on the surface or hidden inside, or even if the rope core is rotten or not, it can check it out for you clearly! This is the real "in-depth physical examination".
It doesn't need to be shut down for too long The detection speed is very fast, greatly reducing the downtime of cranes and not delaying earnings!
Data speaks for itself, giving you a clear idea The inspection results are no longer "rough or possible", but rather clear data and image reports. Can steel wire ropes still be used? When should it be changed? It has scientific basis!
Preventing Major accidents This is the most crucial point! Detect potential hazards in advance, deal with or replace them in a timely manner, and nip the fatal risk of "sudden breakage of steel wire ropes" in the bud! Spending a little money on testing saves a huge amount of safety costs and downtime losses.
Check reports anytime on your mobile phone Weite has some advanced flaw detectors. The detection data can be directly transmitted to the mobile phone APP or computer, allowing you to check the health status of the steel wire rope anytime and anywhere, making management more convenient.
Real case
Old Zhang is in charge of the tower cranes at a large construction site. In the past, I was most afraid of problems with the steel wire rope. Every now and then, I had to send someone to climb up and check on it, feeling extremely anxious. Since using the Weite wire rope flaw detector, regular "physical examinations" have been conducted on the tower crane wire ropes. Once, the instrument gave an alarm, showing that there was a section in the middle of the rope with a lot of broken wires inside, which was completely invisible on the surface! I quickly changed to a new rope. Later, when I took apart that old rope, I found that there were indeed many broken threads inside! Old Zhang said with a shudder, "If it weren't for this instrument, who knows when something big would have happened!" Now I sleep much more soundly."
Construction site Tower cranes and construction hoists, human lives are at stake!
Port terminal Portal cranes and quay cranes are all used to lift valuable goods.
Hydroelectric dam The steel wire rope used in the hoist is related to the safety of the dam.
Mine Safety is of Paramount importance for mine hoists.
Factory workshop Overhead cranes and bridge cranes ensure production safety.
Shipbuilding and Marine Engineering Ship cranes and offshore platform cranes are more prone to damage in harsh environments.
The detection of break points in crane wire ropes is no small matter! Relying solely on the naked eye and experience is too risky. The old methods still have to be used, but to truly feel at ease, we still have to rely on technological meansWire rope flaw detector。
Weite wire rope flaw detectorIt's just like having a 24-hour on-duty "X-ray doctor" for the steel wire rope. Without disassembling or removing it, a quick scan can clearly see all internal and external injuries. Accurate data, clear reports, early warnings, and effectively curbing potential safety hazards! Let our cranes work more safely, the boss be more at ease, and the workers be more reassured!
Safety is no small matter. Never take chances! Let's quickly arrange a "high-tech physical examination" for our steel wire ropes! With the Weite flaw detector, we safeguard safety and protect our jobs!
Tip
The steel wire rope mustRegularlyCheck! Don't wait until something goes wrong to regret!
It is very important to choose reliable flaw detectors and professional inspection services. Weite has been deeply engaged in this field for 23 years, and both its experience and technology are trustworthy.
The test report should be kept well as it is an important safety file!
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