Long lifespan of wire ropes for in-factory transportation using cableways.
This is a case study from a customer in the mining industry. A ropeway has been installed in the factory for transporting materials. When the carrier (the suspended transport device) passes through the support, significant friction occurs between the balance saddle and the wire rope (locked coil), leading to long-standing issues with wire breakage. Additionally, there is a load on the supports, causing loud creaking noises. Issues: 1. Measures are needed to reduce friction at the balance saddle. 2. Since it is an outdoor high location, extensive renovation work is difficult, and welding operations are also challenging. 3. A solution that does not require maintenance is particularly desirable. 4. There are more than 50 locations that require measures.
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Upon checking the current situation, it was confirmed that the balance saddle and wire rope were in contact with each other, resulting in significant sliding resistance. Considering the construction conditions, I proposed a measure to attach the Z-1 liner to the balance saddle area. The Z-1 liner is a high-performance lining material made from ultra-high molecular weight polyethylene (UHMW-PE) with low friction coefficient and excellent wear resistance, molded together with special rubber. Points: 1. Ultra-high molecular weight polyethylene has high slip and wear resistance but is difficult to bond. The Z-1 liner is completely molded with special rubber, allowing the base rubber to be easily bonded to the installation target. 2. The Z-1 liner is available in various thickness specifications according to its application. For this case, a specification with a thickness of 3mm for the ultra-high molecular weight polyethylene and 3mm for the base rubber was selected. 3. The elasticity of the base rubber also contributes to the reduction of impact. 4. The installation points consist of 32 locations on the solid line side (wire rope diameter 50mm) and 32 locations on the dashed line side (wire rope diameter 36mm), totaling 64 locations.
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