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Fatigue life of compacted wire ropes for applications in deep mining

Kubiś Bogusław, Olszyna Grzegorz, Szade Piotr, Tytko Andrzej

Management Systems in Production Engineering

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2023

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nr 1 (31)

95--101

EN

Recent months have highlighted the progressing energy crisis across Europe in connection with the severe sanctions imposed on the import of hydrocarbons and coal from Russia. This is particularly visible in Poland, where over 40% of electricity is generated from coal, while in individual households it is the primary source of heat. This situation puts the already enigmatic plans of shutting down coal mining in Poland into question. Therefore, work aimed at increasing the extraction capacity of existing shafts while maintaining the highest level of operational safety is still valid. This article concerns the issues of the fatigue life of compacted ropes used as hoist ropes in mine shafts. The discussion regarding the use of these ropes among shaft hoist users has been going on for several years. This paper presents the unique results of compacted rope fatigue tests carried out at the Central Mining Institute in Katowice. In the authors’ view, these results and their interpretation should serve to clarify several important aspects that arouse the interest of users.

2

Method for laboratory testing rubber penetration of steel cords in conveyor belts

Woźniak Dariusz, Hardygóra Monika

Mining Science

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2020

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Vol. 27

105--117

EN

As steel cord conveyor belts are vulcanized during the production process, rubber penetrates into steel cords. It is a positive and a desired phenomenon allowing the belt to reach its required properties and ensuring its reliable and long operation on the belt conveyor. Advantageously, the rubber compound penetrating into the cord improves the strength of the cord-rubber joint by increasing the active contact surface of the two materials. This fact is of great significance in the view of the steel cord conveyor belt splicing technology, which relies on an adhesive connection between the cord and the rubber. Moreover, filling the inside of the cords with rubber protects against corrosion and has a good effect on their durability. The article presents a laboratory method for testing and evaluating the penetration of the steel cord with rubber. The method has been developed on the basis of numerous laboratory tests, which are also here described. The presented method is reliable and can be used for a broad range of cord diameters and designs. The proposal also includes a quantitative measure of the rubber penetration of cord and the criteria for its identification.

3

The use of a magnetic flux leakage in the assessment of the technical state of a steel wire rope subjected to bending

Mazurek P., Kwaśniewski J., Roskosz M., Siwoń-Olszewski R.

Journal of KONBiN

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2018

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No. 48

493--513

EN

The technical state of steel wire ropes has a decisive impact on the safety of people using the equipment in which they are installed. The basis for increasing safety is the ability to assess the condition of the working steel wire. The article presents the use of magnetometric sensors to determine the relationship between the number of steel wire rope bends and its magnetic field induction value. This knowledge, referred to ropes working on real objects, allows to determine the state of stress prevailing in them as well as their condition.

PL

Stan techniczny lin stalowych ma decydujący wpływ na bezpieczeństwo ludzi korzystających z urządzeń, w których są zainstalowane. Podstawą zwiększania bezpieczeństwa jest umiejętność oceny stanu kondycji pracującej liny stalowej. W artykule przedstawiono wykorzystanie czujników magnetometrycznych do określenia zależności pomiędzy liczbą przegięć liny stalowej a jej wartością indukcji pola magnetycznego. Wiedza ta, odniesiona do lin pracujących na obiektach rzeczywistych, pozwala określić panujący w nich stan naprężeń a także ich kondycję.

4

The causes of the damage to the bearing rope – failure analysis

Peterka Pavel, Krešák Jozef

Advances in Science and Technology. Research Journal

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2018

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Vol. 12, no 2

231--236

EN

In our laboratory we quite often experience problems with the operation of steel ropes. There is a range of causes related to lifetime problems of ropes. These problems are related to poor quality of input material used for wire production, mixing of different wire strengths in the rope construction, improper roping of the rope into the hoist system, improper rope operation, improper rope design for a particular type of operation as well as unfair practices of vendors. The subject of the article is the analysis of the rope showing the combination of a large number of the above factors leading to the damage of the rope. During the operation of the cargo cableway, the hauling ropes were damaged in a very short time. The Z wires from the surface layer of the rope started to release from the rope. Subsequently, the wires were unwinding from the layer, they created visible protuberant waves, they were braking and dropping out from the rope. The hauling rope had to be replaced. Than the samples were taken from the rope in order to find out the cause of the rope damage. Mechanical, metallographic and fractographic measurements were performed on the rope. The metallographic and fractographic measurements revealed the material defects of the wires of the rope caused during manufacturing of the Z wires from the surface layer of the hauling rope. The mechanical tests revealed differences in the tensile strength grade the operator required compering to the tensile strength grade the vendor declared. The above mentioned problems unambiguously show that it is appropriate to introduce a mechanical control of the rope properties in advance to its deployment. Checks must be performed by an independent testing laboratory. This procedure overprices inputs needed for the rope replacement. On the other hand, it can reduce the costs when a poor quality rope is deployed. Some of our customers have already adopted this approach. It helped to the increase in the safety of the operation of the mechanisms and it eliminated the problems with exchange and climes on bad quality ropes.

5

Experience of the Crane Steel Wire Ropes Non-Destructive Tests

Peterka Pavel, Krešák Jozef, Vojtko Marek

Advances in Science and Technology. Research Journal

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2018

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Vol. 12, no 4

157--163

EN

The non-destructive tests (NDT) of the steel wire ropes put on the crane pulley blocks comprise more than a half of our NDT services. The intensive utilization of cranes often leads to critical situations endangering health and safety at work. The operators are forced to provide safety use of the cranes due to new cranes constructions, new construction of the block pulley and put on the new steel wire rope constructions. The NDT tests of the crane steel wire ropes are coordinate by the Standard ISO 4309. We have experienced only the crane steel wire ropes with an individual wire rope core during our NDT tests so far. The visual NDT test usually used is ineffective to the steel wire ropes with this construction. Based on our previous experience it can be confirmed that surface ruptures are produced after the disintegration of wires inside of a rope; it often leads to the rope abruption during its operation. The reduction of the pulley block dimensions often leads to the problem of the multi-axis rope bending. This kind of the rope line in the pulley block causes the increase of the fretting fatigue of the wires and the rope strands. The same type of the stress is created when the dead ends of the rope are badly constructed.

6

Analiza możliwości identyfikacji stanu wytężenia lin stalowych na podstawie pomiarów właściwości magnetycznych

Kwaśniewski J., Roskosz M., Juraszek J., Schabowicz K., Mazurek P.

Przegląd Spawalnictwa

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2017

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R. 89, nr 11

57--61

PL

Badania nieniszczące lin stalowych to głównie badania defektoskopowe zorientowane na wykrycie pęknięć drutów, deformacji, starć oraz korozji. Jako metody badań stosowane są najczęściej różnego rodzaju metody magnetyczne oraz wizualne. W artykule podjęto analizę możliwości rozszerzenia diagnostyki stanu lin o identyfikację stanu ich wytężenia na podstawie pomiarów zmian właściwości magnetycznych. Wybrane druty liny poddano rozciąganiu i przeprowadzono pomiary własnego magnetycznego pola rozproszenia oraz parametrów impedancji niskoczęstotliwościowej.

EN

Non-destructive testing of steel wire ropes is mainly a flaw detection examination aimed at detection of wire failures, deformations, wear and corrosion. Various types of magnetic and visual methods are used as research methods usually. The article discusses the possibility of extending rope diagnostics to identify the condition of their strain on the basis of measurements of changes in magnetic properties. The selected wire ropes were stretched and measurements of their own magnetic stray field and low frequency impedance parameters were performed.