Publish Time: 2022-07-21 Origin: Site
Wire ropes are essential components in various industrial applications, but their exposure to harsh service environments often leads to corrosion and wear. To ensure durability and longevity, regular lubrication is critical during both production and use. This article explores the importance of lubrication in steel wire rope rigging, and provides an overview of the most effective methods for treating rope core oil, surface oil, and rope surface oil during production.
Due to exposure to abrasive environments, wire ropes are prone to corrosion and wear, which can drastically shorten their service life. Regular lubrication helps to:
Reduce friction between strands and wires
Prevent corrosion and mildew growth
Improve internal lubrication to maintain flexibility and strength
The lubrication process begins with the soaking of the rope core in oil. This crucial step ensures that the inner core of the wire rope is fully lubricated and protected against degradation.
Pre-Treatment: Before oil immersion, the rope core must be carefully dried to remove any moisture. The oil content of the rope core is directly influenced by the drying process, the oil temperature, and the immersion time. The higher the oil content, the better the lubrication and protection.
Oil Immersion Methods:
Atmospheric Pressure Immersion: This method is simpler and allows oil to be absorbed by the outer layers of the rope, but achieving full saturation, especially inside the coil, is difficult. It often results in uneven oil distribution.
Vacuum Oil Immersion: Though more complex, this method ensures even oil absorption across the rope core, with a higher oil content. This process is ideal for ensuring uniform lubrication and protection.
After the rope core has been treated, it is essential to apply surface oil. This step ensures that the outer layers of the wire rope are coated, preventing rust and reducing friction.
Spraying Method: This is done by pressurizing and heating molten liquid oil through an oil pipe. The oil is injected into the joint of the twister and rope machine, filling the spaces between the steel wires and strands.
Dipping Method: After the strands are twisted, the rope can be dipped into a molten grease bath to coat the surface. This method ensures the external surface of the wire rope is adequately lubricated.
While surface oiling methods like spraying and dipping are effective for the outer layers, they often leave the inner layers of the wire rope insufficiently coated. This can lead to increased wear and corrosion in areas that are not properly lubricated.
To improve this, it is recommended to lubricate the steel wires within the strand during the twisting process. This method ensures better penetration of oil into the inner layers, enhancing the overall protection and quality of the wire rope.
In addition to spraying and dipping, there are other techniques for applying oil to wire ropes:
Oil Grooves: Some machines use oil grooves placed between the traction wheel and wire drawing machine. The steel wire ropes are pressed into the molten grease to ensure an even coating.
Oiler Systems: For consistent oil coverage, an oiler can be installed above the wire rope to spray oil as it moves through the machine.
However, these methods can sometimes lead to uneven coatings or holiday coatings on the surface of the wire rope, which may compromise its longevity. Ensuring even oil coverage and deeper penetration into the rope's core is critical for maximum protection.
Lubrication is a vital part of maintaining wire ropes, and using the right methods during production is key to extending their service life. By choosing the proper lubrication techniques—such as rope core oil immersion, spraying, and dipping—you can reduce friction, prevent corrosion, and ensure better performance of wire ropes in challenging environments.
For the best results, ensure that your lubrication practices cover both the core and the surface of the rope, and consider using vacuum oil immersion for more consistent and effective oil distribution.