Rope and Material Test Center PFEIFER SEIL- UND HEBETECHNIK GMBH

Transcription

1 06/2014 SEIL- UND HEBETECHNIK GMBH Rope and Material Test Center DR.-KARL-LENZ-STRASSE 66 D MEMMINGEN TELEFON +49 (0) TELEFAX +49 (0) INTERNET

2 Rope and Material Test Center analyses all properties of wire ropes and applied materials with extensive tests in the central Rope and Material Test Center at the headquarters in Memmingen and with our facilities at DRAKO in Muelheim/Ruhr. If requested, standard tests can be also done locally in our international subsidiaries. Knowing that not only the standard catalog values such as weight per meter and minimum breaking force determine the performance of wire ropes, all properties of the ropes are investigated at in extensive tests. Furthermore, we can ensure the quality of rope end terminations by elaborate material tests. Equipped with this knowledge, we will choose the right wire rope for your application and are able to optimize the lifetime in your equipment. This results in consequence to an economic optimization due to cost savings by reduced downtime and rope replacement costs. Our knowledge your advantage! 2

3 Index Multi Layer Spooling Test Tower....4 Tension Fatigue Test Facility....5 Pull Test Facility....6 Test Facility for Determining Bending Fatigue...8 Rope Efficiency Test Facility....9 Torsion Test Facility...9 Test Facility for Lateral Pressure Resistance Notch Impact Test Hardness Test Spectral Analysis Ultrasonic Elongation and Pull Test Facility Dye Penetrate Test Magnaflux Test Coat Thickness Measuring Microscopic Analysis Measurement Devices In our detailed operating manual "Stranded Ropes for General Lifting Applications" we have summarized information about the correct use of your ropes and give hints how to extend the service life based on current standards and our experience. This is available in many languages both in printed version or as PDF to download at: We are authorized to issue certificates for all kind of ropes. These certificates state that rules and standards in place are met by us. Upon request we provide for example test reports, inspection certificates, certificates of DNV/GL and manufacturer declarations. 3

4 Multi Layer Spooling Test Tower Dimensions (L x W x H): Drive power: 6 m x 4 m x 37,2 m 160 kw Rope layers on the drum: up to 5 Reeving of the load: Test load: up to 7 falls variable, up to 53,6 t All determined values are recorded by direct computer interface. Performing comparative tests with rotation resistant, high performance rotation resistant and non-rotation resistant ropes to obtain detailed knowledge about lifetime and spooling behavior of commercial ropes and to compare the influence of various rope properties. Furthermore development tests with newly developed wire ropes, fiber ropes, new drum systems, drum half shells and other alternatives will be performed. In the test a load is lifted and lowered in fully automatic operation by a drum winch. The test rope is spooled onto the drum in several layers. During lowering the drive is in regenerative mode, the electrical energy is fed back into the grid. The experiments can be run in a 24 hour operation. Based on the findings we can identify the suitability of ropes for the multi layer spooling, as required especially on mobile and tower cranes and select the best rope for OEMs and operators. 4

5 Tension Fatigue Test Facility Tensile force: Frequency: Rope lengths: up to 250 kn up to 5 Hz up to 3 m All determined values are read and recorded by direct computer interface. To test ropes and their rope end terminations on their behavior in periodic loading and unloading operations. Rope test item will be fastened in the attachment and cyclically loaded by a hydraulic cylinder. Our Knowledge your advantage Based on the obtained results we can optimize the rope end termination perfectly matching to the particularly used rope construction. 5

6 Pull Test Facility Determination of the breaking force of the rope system. Wire rope systems (wire rope with rope end termination) are fastened in the device and loaded to breakage or cyclically. Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize the strength of rope end terminations in wire rope systems. Data pull test machine kn (pic. right) Force: up to kn Length: max. 220 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface. pull test 800 kn (pic. bottom) Force: up to 800 kn Length: up to 3 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface. 6

7 Further pull test facilities with capacities up to 2,000 kn: AUSTRIA, Asten CHINA, Shanghai RUSSIA, St. Petersburg ISOFER, Switzerland, Knonau DRAKO Ltd., UK, Crewe USA, Hampton VA MIDDLE EAST, Dubai 7

8 Test Facility for the determination of Bending Fatigue Strength Rope diameter: Force: Rope pulley diameter Standard rope diameter: up to 25 mm up to 200 kn 240 up to 625 mm 16 mm, 22 mm D/d ratio: 16, 20, 22, 25 Angle of inclination variable: 0 bis 4 Determination of the bending fatigue strength of wire ropes by variation of different parameters. Test ropes and sheaves will be installed; by means of an eccentric drive the ropes are bent back and forth over the test sheave. Based on the results of the obtained results we can select the optimum rope construction for applications with high bending cycles or give recommendations for economically D/d ratio. 8

9 Rope Efficiency Test Facility Rope diameter: Rope minimum breaking forces: up to 25 mm up to 700 kn Determination of the efficiency of wire ropes. The test piece is placed over a rope sheave and both rope ends are loaded equally with weights. For the determination of the efficiency extra weight will be added on one side gradually until the internal friction of the rope is exceeded and the rope starts to run over the sheave. The ratio between the additionally applied weight loads to base load calculates into the degree of wire rope efficiency. Knowing the efficiency grade is mainly important in reeving many falls (e.g. reeving of mobile crane hook blocks). Ropes with high efficiency require significantly lower winch drive power when lifting loads and allow to lower only the unloaded hook block, which has great importance for the design and construction of your systems. Torsion Test Facility Force up: Rope lengths: up to 200 kn up to 13 m Determine torque behavior of ropes under load. Ropes will be fastened rotating freely at one end and loaded with defined forces. The resulting rotation is checked by suitable measuring equipment. Also the torque is measured. Based on the gained results we determine the rotation resistance of rotation resistant and high performance rotation resistant ropes and can choose the best rope for your application. 9

10 Test Facility for Lateral Pressure Resistance Rope diameter: up to 25 mm Determination of deformation of wire ropes under lateral pressure. The test rope is inserted between special steel prisms and loaded with defined lateral forces. The changing of the diameter (ovalization) is determined with mathematical precision in the x-and y- direction. Knowledge of the degree of ovalization is essantial in the selection of wire ropes for use in multi layer spooling. Notch Impact Test Notch impact energy: 300/150 J Determining the material toughness depending on the temperature. The specimen (sample of material) is fixed on each end and the impact pendulum hammer hits the middle of the specimen at the level of the previously machined notch. The sample breaks at the notch and absorbs a specific energy. On the basis of the remaining energy in the hammer, the material toughness at a specific temperature can be determined. Ensuring the material toughness is crucial in the selection and processing of material for rope end terminations.. 10

11 Spectral Analysis Optical Emission Spectrometer for metal analysis Non-destructive determination of the chemical material composition. In the optical emission spectrometry atoms of the probe are stimulated with energy from a spark that is created between the sample and the electrode. Through the energy of the spark the electrons in the sample emit light, which is transmitted into a spectral grid. By measuring the intensity of the spectral lines, the material composition can be precisely determined. Material for rope end terminations will only be selected or processed if we know and can permanently secure the chemical composition of the materials. Ultrasonic Max. material thickness: up to mm Non-destructive testing of components for material defects such as bubbles, cracks or transverse defects. The principle of ultrasonic testing is based on the fact that sound waves propagate at different speeds in different media. Changes in acoustic properties at interfaces (for example, voids, inclusion, tear) in the interior of the part to be tested reflect the ultrasound pulse and send it to the vibrator in the probe, which acts both as transmitter and receiver. Based on the measured time difference, a signal image is produced and displayed on a monitor. Through this image, the position and the size of the error can be determined. The guarantee of error-free components is crucial for us in the selection and processing of materials for wire rope end terminations. Hardness Test Hardness testing acc. Rockwell, Brinel, Vickers Force range: 1 bis 250 kg All determined values are read and recorded by the direct computer connection. Traditional hardness testing of metals and plastics. The hardness test equipment tests acc. Rockwell and determines the ball indentation hardness. In addition all common optical hardness testing methods (Vickers, Brinell) and depth measurements (Rockwell) conforming to standards are covered in the load range. In order to correctly select and process the material for rope end terminations, we must know and permanently secure the material hardness. 11

12 Elongation and Pull Test Facility Force: up to 50 kn Length: max mm Tension fatigue tests possible All determined values are read and recorded by direct computer interface. Determination of elongation behavior as well as rope system and material breaking forces. Rope systems (rope with rope end termination) and material samples are fastened in the attachments and loaded for elongation or eventually until destruction rsp. loaded cyclically. Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize rope end terminations in rope systems. Also knowing and ensuring the material properties is essential for us in the selection and processing of materials for rope end terminations. Dye Penetration Test Dye Penetration Test acc. DIN EN The dye penetration test is a non-destructive material test, in which the capillary forces of almost invisible superficial cracks and pores are used to make them visible. At dye penetration testing the penetrant dye (Contraster) is applied to the surface of the sample. The creep properties of the penetrant is high, uses the capillary action of the finest material separations and has a strong color contrast to the developer. After the exposure time depending on the material the surface is cleaned, dried and the developer is applied. The developer is a fine-grained powder suspension with a suitable solvent. Due to the capillary action of its internal cavities, it draws out remaining penetrant dye from the superficial cracks. The high color contrast makes it easy to locate the flaw positions and to determine the crack paths. Through the examination of the rope end terminations we can guarantee impeccable quality and safe usability. 12

13 Magnaflux Test Magnaflux Test acc. DIN EN The magnaflux test is a method for the detection of cracks in or near the surface. Suspended iron powder is applied to the test object. By magnetization and suitable lighting even the finest hairline cracks can be recognized. The guarantee of perfect quality of the materials is the basis for error-free rope end terminations and thus secure rope systems. 13

14 Coating Thickness Measuring Coulometric layer thickness measuring acc. DIN EN ISO 2177 Determination of the metallic layer thickness on components such as zinc layer thickness on wires of rope. In the coulometric coating thickness measurement, a metal layer is replaced by an electrolyte from its metallic or nonmetallic base material by a controlled electrical current flow, thus reversal of the electroplating process. The required amount of electrical curent for the layer separation is directly proportional to the replaced metal mass. The result is a clear correlation between release time and layer thickness since release and the current release surface are kept constant. Magnetic inductive measurement acc. DIN EN ISO 2178 Determination of the galvanic layer thicknesses on metallic construction parts e.g. zinc layer thickness on wires of steel cables. At the magnetic induction method a magnetic flux is generated by a current in the primary coil of an electromagnet, which in turn develops an inductive voltage. The layer thickness is determined by measuring the change of the magnetic flux, and thus the induced voltage. The knowledge and ensuring the metallic layer thicknesses (e.g. galvanizing of steel cables) for us are critical in the selection and processing of steel cables. 14 Microscopic Analysis Microscope with camera, 60-times magnification 150 watt halogen cold light gooseneck light conductor All determined values are read and recorded by direct computer interface. Determination of microscopic changes on specimens. The specimen is clamped, illuminated by halogen cold light and the area to be examined displayed visually enlarged at the monitor. The knowledge and ensuring the material properties are crucial in the selection and processing of our materials. Similar microscopic inspections in rope investigations are necessary.

15 -measurement devices: by pros for pros! Measurement devices Based on our long-term practical experience of rope drive inspection, we created the following measurement devices kit. These measurement devices are used by our rope experts for each inspection and thereby approved for general use. Rope caliper 40 With attached wide jaws Product advantages Recommended for frequent measurement of ropes with the most common diameters up to 40 mm Enables quick and easy check wide jaws reduce measuring faults Measurement equipment case 75 Content: Rope caliper 75 made of galvanized steel with attached wide jaws Recommended for the frequent measuring of ropes in the most common diameters Rope diameter 5 28 mm, mm, mm, 5 60 mm Further combinations of the 5 different groove gauges kits on request Product advantages Combine your own measurement equipment case according to your needs! Rope caliper 150 With attached extra wide jaws and adapter plates for big rope diameters Product advantages Recommended for frequent measurement of ropes with diameters up to 150 mm Enables quick and easy check wide jaws reduce measuring faults Propeller Stainless steel Rope diameter 15 mm, 20 mm, 24 mm Further sizes on request Product advantages Recommended for the frequent check of rope drives with a specific diameter Measurement equipment case 150 Content: Rope caliper 150 Groove gauges Bolt with 5 kits (see picture measurement equipment case 75) Rope diameter 5 60 mm Product advantages The complete measurement equipment case for the frequent professional groove inspection! Ring Stainless steel Rope diameter 5 20 mm, mm, mm, mm Product advantages Recommended for the frequent check of rope drives with the most common rope diameters Rope service starter kit Content: 2x RL-S Wire rope lubrication Spray can 1x Groove-gauge-Kit Worker 1x Pair gloves 1x Rope caliper 40 1x Yard stick 1x Steel wire brush Product advantages Allows quick and easy control as well as professional care of your wire ropes 15

16 Our Locations Worldwide Toronto St. Petersburg Hampton Moscow Crewe Rio de Janeiro Southampton Hamburg Berlin Mülheim Wrocław Schifflange Changshu Shanghai Memmingen Knonau Asten Budapest Bilbao Singapur Barcelona Madrid Dubai GERMANY MEMMINGEN TEL FAX MÜLHEIM TEL FAX Service-Centres in: Berlin, Hamburg and additional test service centre in Mannheim SPAIN MADRID TEL FAX BARCELONA TEL FAX BILBAO TEL FAX AUSTRIA ASTEN TEL FAX SWITZERLAND KNONAU TEL FAX RUSSIA MOSCOW TEL FAX ST. PETERSBURG TEL FAX LUXEMBOURG SCHIFFLANGE TEL FAX UAE DUBAI TEL FAX HUNGARY BUDAPEST TEL FAX POLAND WROCŁAW TEL FAX BRAZIL RIO DE JANEIRO TEL CHINA SHANGHAI TEL FAX USA HAMPTON TEL FAX GREAT BRITAIN CREWE TEL FAX SOUTHAMPTON TEL FAX WA/pdf