CN112197986A - Reliability test method for steel wire rope double-twisting machine - Google Patents
Reliability test method for steel wire rope double-twisting machine Download PDFInfo
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- CN112197986A CN112197986A CN202010981993.0A CN202010981993A CN112197986A CN 112197986 A CN112197986 A CN 112197986A CN 202010981993 A CN202010981993 A CN 202010981993A CN 112197986 A CN112197986 A CN 112197986A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
- G01M99/008—Subject matter not provided for in other groups of this subclass by doing functionality tests
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
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Abstract
The invention discloses a reliability test method for a steel wire rope double-twisting machine, wherein an equipment no-load test-test prototype starts to run step by step from an initial working rotating speed which is 25-35% of the maximum value of a rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the lubrication condition of a bearing seat in a take-up assembly is observed; and (3) performing a loading test of the equipment, namely sequentially operating step by step at an initial working rotating speed of 25-35% of the maximum value of the rated rotating speed, increasing the speed of each step to 8-12% of the initial working rotating speed, detecting whether the twisted stranded rope is qualified or not, and performing temperature rise measurement, vibration detection and noise measurement if the twisted stranded rope is qualified. The reliability test method for the steel wire rope double twister can quickly verify after the equipment is assembled, does not need to go to a client side or an outfield test, has short period and low cost, finds problems in time, and can effectively check the reliability of the equipment.
Description
Technical Field
The invention belongs to the technical field of double-twisting machine complete machine tests, and particularly relates to a reliability test method for a steel wire rope double-twisting machine.
Background
A steel wire rope double-twisting machine is a rope or strand stranding production device suitable for elevator steel wire ropes, basket steel wire ropes and steel wire ropes for adhesive tapes. The ability of a device to perform a specified function within a certain time and under certain conditions without failure directly determines the reliability of the device. The steel wire rope double-twisting machine consists of mechanical parts and an electric control system, and has a complex structure and mutual correlation. At present, most of the reliability assessment of equipment is carried out in a client side test or an external field test, the test period is long, the test cost is high, and the time for finding problems is late, so that the satisfaction of a client and the development progress of the equipment are directly influenced.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a method for testing the reliability of a steel wire rope double twister, which can quickly verify whether equipment reaches design indexes after the equipment is assembled, and has the advantages of short period, low cost and high reliability.
In order to achieve the purpose, the reliability test method of the steel wire rope double-twisting machine comprises a wire collecting assembly, an outer over-twisting assembly, a wire collecting assembly, a single wire paying-off assembly, a core wire paying-off assembly and an electric control cabinet; the test method comprises an idle load test and a loading test, and comprises the following specific test steps:
1) installation of equipment
2) No-load test of equipment
2a) The inspection test prototype starts to run under the condition of no load;
2b) the test sample machine starts to operate step by step from an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, and the speed of each step is gradually increased to be 8-12% of the initial working rotating speed; meanwhile, when the working rotating speed is 78-82% of the maximum rated rotating speed, the running time is 2-3 h;
2c) after the step 2b) is finished, observing the lubricating condition of a bearing seat in the take-up assembly, and recording test data;
3) equipment loading test
3a) Preparation and setting of process parameters for loading test
3b) Initiation of the Loading test
3b1) Checking each part and starting to operate, observing whether the take-up assembly, the external over-twisting assembly, the wire collecting assembly, the monofilament paying-off assembly and the core wire paying-off assembly are abnormal, and then operating at the initial working speed of 25-35% of the maximum rated speed;
3b2) sequentially operating step by step at an initial working rotating speed of 25-35% of the maximum value of the rated rotating speed, wherein the speed of each step is increased to 8-12% of the initial working rotating speed, and meanwhile, when the working rotating speed is 70-75% of the maximum value of the rated rotating speed, operating for 2-3 h and detecting whether the twisted strand is qualified or not;
if the twisted stranded rope is unqualified, finding the reason, checking whether each part is assembled in place or not, whether each wire passing path is smooth or not, or adjusting the process parameters in the step 3 a); and if the twisted strand is qualified, performing temperature rise measurement, vibration detection and noise measurement.
Further, the temperature rise measurement specifically comprises the following steps:
the test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min;
after each stage of rotating speed runs for 10-20 min, the temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are respectively measured, the working temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are all less than 80 ℃, and the temperature rise of each stage is lower than 30-40 ℃;
measuring the temperature of the gearbox body of the variable speed gearbox after each stage of rotation speed runs for 10-20 min, and evaluating indexes: the working temperature of the gearbox body is less than 80 ℃, and the temperature rise of each stage is less than 30-40 ℃;
and test data was recorded.
Further, the vibration detection specifically comprises the following steps:
the test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min; detecting the vibration value of each zero part of the equipment, wherein the detection items and the evaluation indexes are as follows:
1) the vibration value of the spinning wheel shaft assembly is less than 3 mm/s;
2) the vibration value of the main transmission shaft assembly is less than 3 mm/s;
3) the vibration value of the over twister is less than 3 mm/s;
4) the vibration value of the monofilament paying-off machine frame is less than 5 mm/s;
5) the shaking angle of the cradle is within the range of +/-15 degrees;
and test data was recorded.
Further, the specific process of the noise measurement is as follows:
after the test sample machine is sequentially and respectively operated for 2-3 h according to 30%, 50% and 80% of the maximum value of the rated rotating speed, the noise is measured;
placing a noise measuring instrument at a position which is 1-1.2 meters away from the equipment horizontally and 1.5-1.6 meters high, and respectively measuring the noise of the front side, the back side, the left side and the right side of the hood;
the noise level of the test sample machine under different rotating speeds is examined, and the noise level measured by the test sample machine is not more than 85dB according to the regulation of GB/T4215-1984;
and test data was recorded.
Further, in the step 2a), the operation time of each stage of speed is 5-10 min, and the total no-load operation time is 4-5 h.
Further, in the step 3a), the preparation and setting of the process parameters of the loading test are as follows:
3a1) determining a test twisting structure, placing a corresponding number of paying-off I-shaped wheels according to paying-off stations of the equipment, and ensuring that the paying-off I-shaped wheels do not interfere after threading and the running of the wire passing wheels is flexible; then, the paying-off tension is adjusted to a process set value, and the tension error of each paying-off station is less than +/-0.25 Kg;
3a2) installing a line concentration eye film of the line concentration assembly, ensuring that the center height of the line concentration eye film is consistent with that of the line collection assembly and the line release assembly, ensuring that the error is less than +/-0.5 mm, and adjusting the twisting angle according to a process set value;
3a3) winding the take-up assembly and setting technological parameters
The process parameters comprise a take-up process speed, an over-twisting take-up speed ratio, a take-up lay length, a take-up meter coefficient, a monitoring meter coefficient, acceleration time, deceleration time and quick stop time.
Further, in the step 3b1), the wire take-up assembly, the outer over-twisting assembly, the wire collecting assembly, the monofilament paying-off assembly and the core wire paying-off assembly run for 5-10 min after no abnormality exists, and the initial working speed runs for 10-15 min.
Further, in the step 3b1), safety protection devices and safety tests are performed during the operation of the initial working rotating speed, which are as follows:
a. single-wire broken wire protection test: when the equipment runs, cutting off each single wire in sequence, observing whether the equipment is stopped synchronously or not, and ensuring that the reaction time of the equipment stopping action does not exceed 1 second;
b. and (3) wire breakage protection test: the equipment is firstly stopped, any single wire is cut at any position between the over-twisting device and the gearbox, then the equipment is started to operate, the broken end passes through the broken wire detection copper plate on the side edge of the gearbox, whether the equipment is synchronously stopped or not is observed, and the stop action reaction time of the equipment is not more than 1 second.
Further, in the step 3b2), the operation time of each stage speed is 5-10 min.
Compared with the prior art, the invention has the following advantages: the reliability test method for the steel wire rope double twister can quickly verify after the equipment is assembled, does not need to go to a client side or an outfield test, has short period and low cost, finds problems in time, and can effectively check the reliability of the equipment.
Detailed Description
The present invention will be described in further detail with reference to specific examples.
The steel wire rope double-twisting machine in the reliability test method of the steel wire rope double-twisting machine comprises a wire collecting assembly, an outer over-twisting assembly, a wire collecting assembly, a single wire paying-off assembly, a core wire paying-off assembly and an electric control cabinet. The test verification project of the steel wire rope double twister mainly comprises a no-load test and a loading test, wherein the loading test comprises a temperature rise test, vibration detection and noise measurement, and the specific test steps are as follows:
1) detection tool and preparation instrument before test
The instrument comprises an infrared thermometer, a noise detector and a vibration tester;
2) pre-test equipment inspection
The equipment is checked before the test, and the assembly of all parts of the equipment is ensured to meet the requirements of a design atlas;
3) no-load test of equipment
3a) The inspection test prototype starts to run under the condition of no load;
3b) the test sample machine starts to operate step by step from an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 5-10 min; meanwhile, when the working rotating speed is 78-82% of the maximum rated rotating speed, the running time is 2-3 h, and the total no-load running time is 4-5 h;
3c) after the step 3b) is finished, the lubricating condition of a bearing seat in the take-up assembly is observed: the good lubrication is ensured, and the phenomena of oil leakage, oil leakage and the like are avoided; and (3) observing the loosening condition of each part of the steel wire rope double-twisting machine: all fasteners and connecting pieces should not be loosened; observe the aircraft bonnet condition of opening and shutting: the hood is convenient to open and close, and the safety interlocking device is sensitive and reliable; and recording test data;
4) equipment loading test
4a) Preparation of Loading test
4a1) Determining a test twisting structure, placing a corresponding number of paying-off I-shaped wheels according to paying-off stations of the equipment, and ensuring that the paying-off I-shaped wheels do not interfere after threading and the running of the wire passing wheels is flexible; then, the paying-off tension is adjusted to a process set value, and the tension error of each paying-off station is less than +/-0.25 Kg;
4a2) installing a line concentration eye film of the line concentration assembly, ensuring that the center height of the line concentration eye film is consistent with that of the line collection assembly and the line release assembly, ensuring that the error is less than +/-0.5 mm, and adjusting the twisting angle according to a process set value;
4a3) winding the take-up assembly and setting technological parameters
The process parameters comprise a take-up process speed, an over-twisting take-up speed ratio, a take-up lay length, a take-up meter coefficient, a monitoring meter coefficient, acceleration time, deceleration time and quick stop time;
4b) initiation of the Loading test
4b1) Checking whether each part meets the design state and has no abnormal phenomena such as interference and the like, starting to operate, observing whether the take-up assembly, the external over-twist assembly, the wire collection assembly, the monofilament paying-off assembly and the core wire paying-off assembly are abnormal and operating for 5-10 min, and then operating for 10-15 min at the initial working rotating speed of 25-35% of the maximum value of the rated rotating speed;
and carrying out safety protection devices and safety tests during the initial working rotating speed operation:
a. single-wire broken wire protection test: when the equipment runs, sequentially cutting off each single wire, and observing whether the equipment is synchronously stopped;
b. and (3) wire breakage protection test: the equipment is firstly stopped, any single wire is cut at any position between the over-twister and the gearbox, then the equipment is started to operate, the broken end passes through the broken wire detection copper plate at the side of the gearbox, and whether the equipment is synchronously stopped or not is observed;
or adding a steel wire broken end before the wire concentration eye die when the initial working rotating speed is operated for testing;
evaluation indexes are as follows: the reaction time of the equipment stopping action is not more than 1 second;
4b2) sequentially operating at an initial working rotating speed of 25-35% of the maximum value of the rated rotating speed step by step, wherein the speed of each step is increased to 8-12% of the initial working rotating speed, and the operating time of each step is 5-10 min; meanwhile, when the working rotating speed is 70-75% of the maximum rated rotating speed, the running time is 2-3 h, and then whether the twisted stranded rope is qualified is detected;
if the twisted strand is not qualified, finding the reason, checking whether each part is assembled in place and whether each wire passing path is smooth, or adjusting the process parameters of the step 4a 3); if the twisted strand is qualified, temperature rise measurement, vibration detection and noise measurement are carried out;
4b3) temperature rise measurement
The test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min;
and after each level of rotating speed runs for 10-20 min, the temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are respectively measured, and the indexes are evaluated: the working temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are all less than 80 ℃, and the temperature rise of each stage is less than 30-40 ℃;
measuring the temperature of the gearbox body of the variable speed gearbox after each stage of rotation speed runs for 10-20 min, and evaluating indexes: the working temperature of the gearbox body is less than 80 ℃, and the temperature rise of each stage is less than 30-40 ℃;
and recording test data;
4b4) vibration detection
The vibration value measuring method and the operation condition are specified in GB/T6075.1-2012 chapter 3;
the test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min; detecting the vibration value of each zero part of the equipment, wherein the detection items and the evaluation indexes are as follows:
1) the vibration value of the spinning wheel shaft assembly is less than 3 mm/s;
2) the vibration value of the main transmission shaft assembly is less than 3 mm/s;
3) the vibration value of the over twister is less than 3 mm/s;
4) the vibration value of the monofilament paying-off machine frame is less than 5 mm/s;
5) the shaking angle of the cradle is within the range of +/-15 degrees;
and recording test data;
4b5) noise measurement
After the test sample machine is sequentially and respectively operated for 2-3 h according to 30%, 50% and 80% of the maximum value of the rated rotating speed, the noise is measured;
placing a noise measuring instrument at a position which is 1-1.2 meters away from the equipment horizontally and 1.5-1.6 meters high, and respectively measuring the noise of the front side, the back side, the left side and the right side of the hood;
the noise level of the test sample machine under different rotating speeds is examined, and the noise level measured by the test sample machine is not more than 85dB according to the regulation of GB/T4215-1984;
and recording test data;
5) reliability assessment
When the no-load test and the loading test both pass smoothly and no abnormality occurs, the reliability test of the whole machine operation is determined to be qualified; if any one of the tests is abnormal, the reason is found out, the test is corrected, and then a repeated test is carried out.
The reliability test method for the steel wire rope double twister can quickly verify after the equipment is assembled, does not need to go to a client side or an outfield test, has short period and low cost, finds problems in time, and can effectively check the reliability of the equipment.
Claims (9)
1. A reliability test method for a steel wire rope double-twisting machine comprises a wire collecting assembly, an outer over-twisting assembly, a wire collecting assembly, a single wire paying-off assembly, a core wire paying-off assembly and an electric control cabinet; the method is characterized in that: the test method comprises an idle load test and a loading test, and comprises the following specific test steps:
1) installation of equipment
2) No-load test of equipment
2a) The inspection test prototype starts to run under the condition of no load;
2b) the test sample machine starts to operate step by step from an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, and the speed of each step is gradually increased to be 8-12% of the initial working rotating speed; meanwhile, when the working rotating speed is 78-82% of the maximum rated rotating speed, the running time is 2-3 h;
2c) after the step 2b) is finished, observing the lubricating condition of a bearing seat in the take-up assembly, and recording test data;
3) equipment loading test
3a) Preparation and setting of process parameters for loading test
3b) Initiation of the Loading test
3b1) Checking each part and starting to operate, observing whether the take-up assembly, the external over-twisting assembly, the wire collecting assembly, the monofilament paying-off assembly and the core wire paying-off assembly are abnormal, and then operating at the initial working speed of 25-35% of the maximum rated speed;
3b2) sequentially operating step by step at an initial working rotating speed of 25-35% of the maximum value of the rated rotating speed, wherein the speed of each step is increased to 8-12% of the initial working rotating speed, and meanwhile, when the working rotating speed is 70-75% of the maximum value of the rated rotating speed, operating for 2-3 h and detecting whether the twisted strand is qualified or not;
if the twisted stranded rope is unqualified, finding the reason, checking whether each part is assembled in place or not, whether each wire passing path is smooth or not, or adjusting the process parameters in the step 3 a); and if the twisted strand is qualified, performing temperature rise measurement, vibration detection and noise measurement.
2. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: the temperature rise measurement process comprises the following steps:
the test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min;
after each stage of rotating speed runs for 10-20 min, the temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are respectively measured, the working temperatures of the left bearing seat, the right bearing seat and the flywheel shaft are all less than 80 ℃, and the temperature rise of each stage is lower than 30-40 ℃;
measuring the temperature of the gearbox body of the variable speed gearbox after each stage of rotation speed runs for 10-20 min, and evaluating indexes: the working temperature of the gearbox body is less than 80 ℃, and the temperature rise of each stage is less than 30-40 ℃;
and test data was recorded.
3. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: the vibration detection comprises the following specific processes:
the test sample machine sequentially operates step by step at an initial working rotating speed which is 25-35% of the maximum value of the rated rotating speed, the speed of each step is increased to be 8-12% of the initial working rotating speed, and the operating time of each step is 10-20 min; detecting the vibration value of each zero part of the equipment, wherein the detection items and the evaluation indexes are as follows:
1) the vibration value of the spinning wheel shaft assembly is less than 3 mm/s;
2) the vibration value of the main transmission shaft assembly is less than 3 mm/s;
3) the vibration value of the over twister is less than 3 mm/s;
4) the vibration value of the monofilament paying-off machine frame is less than 5 mm/s;
5) the shaking angle of the cradle is within the range of +/-15 degrees;
and test data was recorded.
4. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: the specific process of noise measurement is as follows:
after the test sample machine is sequentially and respectively operated for 2-3 h according to 30%, 50% and 80% of the maximum value of the rated rotating speed, the noise is measured;
placing a noise measuring instrument at a position which is 1-1.2 meters away from the equipment horizontally and 1.5-1.6 meters high, and respectively measuring the noise of the front side, the back side, the left side and the right side of the hood;
the noise level of the test sample machine under different rotating speeds is examined, and the noise level measured by the test sample machine is not more than 85dB according to the regulation of GB/T4215-1984;
and test data was recorded.
5. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: in the step 2a), the running time of each stage of speed is 5-10 min, and the total no-load running time is 4-5 h.
6. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: in the step 3a), the preparation and setting of the process parameters of the loading test are as follows:
3a1) determining a test twisting structure, placing a corresponding number of paying-off I-shaped wheels according to paying-off stations of the equipment, and ensuring that the paying-off I-shaped wheels do not interfere after threading and the running of the wire passing wheels is flexible; then, the paying-off tension is adjusted to a process set value, and the tension error of each paying-off station is less than +/-0.25 Kg;
3a2) installing a line concentration eye film of the line concentration assembly, ensuring that the center height of the line concentration eye film is consistent with that of the line collection assembly and the line release assembly, ensuring that the error is less than +/-0.5 mm, and adjusting the twisting angle according to a process set value;
3a3) winding the take-up assembly and setting technological parameters
The process parameters comprise a take-up process speed, an over-twisting take-up speed ratio, a take-up lay length, a take-up meter coefficient, a monitoring meter coefficient, acceleration time, deceleration time and quick stop time.
7. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: in the step 3b1), the winding-up assembly, the external over-twisting assembly, the wire collecting assembly, the monofilament paying-off assembly and the core wire paying-off assembly all operate for 5-10 min after no abnormity, and the initial working speed operates for 10-15 min.
8. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: in step 3b1), safety devices and safety tests are performed during the initial operating speed, specifically as follows:
a. single-wire broken wire protection test: when the equipment runs, cutting off each single wire in sequence, observing whether the equipment is stopped synchronously or not, and ensuring that the reaction time of the equipment stopping action does not exceed 1 second;
b. and (3) wire breakage protection test: the equipment is firstly stopped, any single wire is cut at any position between the over-twisting device and the gearbox, then the equipment is started to operate, the broken end passes through the broken wire detection copper plate on the side edge of the gearbox, whether the equipment is synchronously stopped or not is observed, and the stop action reaction time of the equipment is not more than 1 second.
9. The method for testing the reliability of a steel wire rope double twister according to claim 1, wherein: in the step 3b2), the running time of each stage of speed is 5-10 min.
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| CN113699812A (en) * | 2021-08-23 | 2021-11-26 | 湖北三江航天江北机械工程有限公司 | Wire rope line concentration equipment |
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