When Should We Replace the Wire Rope and How to Replace the Wire Rope

Wire Rope is the key component of hoisting mechanism for an Overhead Crane,it affects the safety of crane greatly.Thus it's really important for our overhead crane operator to judge whether the wire rope need to replace and learn how to replace the wire rope.

Today I will share you some tips,hope it will be helpful to you.

When judge the problem of wire rope, observe the principle of:
The rope is straight with load, and twist without load: cranes problem.
The following situations which shown in the photos are common damaged wire ropes; discard it according the actual situation.

	Mechanical damage due to rope movement over sharp edge projection whilst under load.
	Localised wear due to abrasion on supporting structure.
	Narrow path of wear resulting in fatigue fractures, caused by working in a grossly oversize groove, or over small support rollers.
	Two parallel paths of broken wires indicative of bending through an undersize groove in the sheave.
	Severe wear, associated with high tread pressure.
	Severe wear in Lang`s Lay, caused by abrasion.
	Severe corrosion.
	Typical wire fractures as a result of bend fatigue.
	Wire fractures at the strand, or core interface, as distinct from `crown` fractures.
	Break up of Independent Wire Rope Core resulting from high stress application.
	Looped wires as a result of torsional imbalance and/or shock loading.
	Typical example of localised wear and deformation.
	Multi strand rope `bird caged` due to torsional imbalance.
	Protrusion of rope center resulting from buildup of turn.
	The appearance of the independent steel core convex caused by the impact load.

Replacement of wire rope

a) Remove the rope guide.

b) Lower the hook set onto the support. Remove the old wire rope from the rope end fixture and connect the rope to the end of the old wire rope with a clamp, then use the auxiliary lifting machine to lower the old wire rope tail to the ground.

c) Fix the old wire rope tail to the empty drum, drive the reel and the empty drum, and wrap the old wire rope around the empty drum. See picture below.

d) Wrap the old wire rope until the wire rope on the drum is reduced to the vicinity of the pressure plate and remove the first pressure plate near the end of the rope. See picture below.

e) Connect the tail of the wire rope to the nylon rope, fix the nylon rope to the auxiliary hoisting machine, remove the remaining pressure plate, and lower the wire rope to the ground.

f) Wrap the new wire rope on the pulley as it is, one end of wire rope fixed to the rope end device and the other end of wire rope fixed to the pressure plate on the drum.

g) When the power is turned on, the wire rope will wrap the drum after lifting the hook.