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  Return to Wire Rope Main Page and Detailed Wire Rope Data  
    Technical Information  
  Use and Care of Wire Rope  
  Wire Rope is a Machine  
    Installation of Wire Rope:  
  Foreword, Measuring the rope diameter  
  If you have to cut a rope  
  Unreeling the rope  
  Connecting the old rope to the new rope  
  Rope lay direction versus Drum Grooving  
  Winding on to the drum  
  Installation of Wedge Sockets  
  Using your rope for the first time  
  Efficiency ratings of end terminations  
    Inspection of Wire Rope:  
  How to inspect Wire Rope  
  Crown- and Valley Wire Breaks  
  Number of broken Wire Discard Tables  
  Reduction of diameter, Rope Wear  
  Rope Stretch, Core Wire breaks  
  Mechanical damages  
  Corrosion, Rope Removal and Cause  
    Maintenance:  
  Inspection of Sheaves and Drums, Dimensions of Groove Radius  
  Cut and Slip Procedure, Lubrication  
    Rope Properties & Data:  
  Tensile Strength and Fill Factor  
  Strand- and Swage Compaction  
  Rotation Resistant and Non-Rotating Wire Rope  
  Sheave and Drum Dimensions  
  Relative Service Life, Loss of Strength over Pins, Why Multistrand Ropes  
Technical Information – Maintenance
     
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Inspection of Sheaves and Drums

Proper maintenance of the equipment on which the ropes operate has an important bearing on rope life. Worn grooves, poor alignment of sheaves and worn parts resulting in shock loads and excessive vibration will have a deteriorating effect.

Sheaves should be checked periodically for wear in the grooves which may cause pinching, abrasion, and bird-caging of the rope. If the groove shows signs of rope imprints the sheave must be replaced or re-machined and re-hardened. The same should be done on drums showing similar effect.

Poor alignment of sheaves will result in rope wear and wear on the sheave flange. This should be corrected immediately.

Excessive wear in the sheave bearings can cause rope fatigue from vibration.
Large fleet angles will cause severe abrasion of the rope as it winds onto the drum.

Furthermore, the rope will roll into the sheave groove introducing torque and twist which may cause high stranding and bird-cages.
  Dimension of the Groove Radius

The very first item to be checked when examining sheaves and drums, is the condition of the grooves. To check size, contour and amount of wear, a groove gauge is used.

Two types of groove gauges are in general use and it is important to note which of these is being used. The two differ in their percentage over the Nominal Rope Diameter.

For new or remachined grooves, and for inspection of fitness for new ropes, the groove gauge should be 1% over the maximum allowable Plus Tolerance of the new rope; alternately, the sheave groove must measure 1% over the Actual Rope Diameter intended to be installed.

Many groove gauges on the market are so called 'No-Go' gauges and are made with Nominal plus 1/2 of permissible rope Plus Tolerance. If you use these gauges be sure that the existing rope is SMALLER than this gauge. A rope operating in an even slightly undersized groove, deteriorates faster and may develop bird-cages.
     
      Sheave gauges for rope sizes ranging from 8mm to 32mm and 1/4" to 1-1/2" are available from Unirope.
Check bearings for wobble, lubrication & ease of rotation
Properly matched rope & sheave groove
Sheave groove too small
Sheave groove is undercut
New rope will get
damaged beyond repair
A sheave corrugated by the rope's 'print'. This sheave will damage the rope
     
     
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