EP3691811B1 - Rope drum and method for the production thereof - Google Patents

Description

The present invention relates to rope drums for winding and unwinding ropes, with a drum shell to which end plates are fastened at the front, and rope winches with such rope drums. The invention also relates to a method for producing such a cable drum.

Cable winches are used in various areas of application and essentially comprise three large main assemblies, namely, on the one hand, the cable drum with a drum shell and end or flanged disks attached to the front side, which limit the drum shell, on the other hand, a drive gear and finally a winch frame on which the cable drum is rotatably mounted is. The drive gear mentioned is often housed inside the cable drum and can be designed, for example, as a single-stage or multi-stage planetary gear.

The font DE 393 583 C shows, for example, a cable drum that has a cylindrical core made of cast iron, onto which a sheet metal jacket with pressed or rolled cable grooves is pushed. More winches of the type mentioned are for example from the writings US 1,991,486A , GB 24 90 350 A , JP H05 97395 A or JP S50 84455 A known.

Such cable winches are used, for example, for charging systems such as lime kiln charging systems or hoists in mechanical and plant engineering or in handling technology or systems in the mining and raw materials industry, whereby the cable winches can be used for vertical material transport, but also as a horizontal or inclined feed drive . Other applications can include cranes such as construction cranes, mobile cranes or maritime cranes such as port, Be ship and offshore cranes, the cable winches here can be hoist winches for winding and unwinding a hoist rope, but also guy winches for guy ropes or feed winches, for example, to move a trolley. Such cable winches are also used for other construction machines such as crawler cranes and can also be used as derrick winches or deep-sea winches.

Depending on the application, such cable winches can be very large, with corresponding large cable winches or heavy-duty cable winches having considerable dimensions with diameters of several meters and unit weights of 10 t, 20 t or even more tons.

Considerable compressive stresses occur on the cable drum as a result of the cable to be spooled under load, under which the cable drum must hold the package of cables wound thereon with sufficient safety. The rope to be wound up is not only wound up in one layer, but in several layers - also more than ten layers - stacked on top of each other and wound up on the rope drum, whereby each individual layer to be wound up in turn introduces compressive stresses into the rope drum tube, so that according to the superposition principle in itself constant cable pull, the compressive stresses in the drum shell increase more and more with an increasing number of winding layers. If, for example, a rope pull of 100 kN with a single-layer winding constricts the rope drum tube with a force of around 100 kN, several winding layers result in considerably higher forces acting on the tube, which, for example, with ten or more winding layers are a multiple of the 100 kN mentioned and also can exceed 1000 kN.

The drum casing has to withstand this external pressure, so that in some cases considerable drum wall thicknesses are provided and, for example, drum wall thicknesses of 50-150 mm can make sense. Some of the cable drum tubes are also made of high-strength steels such as heat-treatable steels or fine-grain structural steels in order to save weight while still being able to withstand the high pressure loads.

In order to be able to efficiently manufacture large cable drum tubes in the dimensions mentioned, sheets are usually burned out, rounded and welded together at the joints. A rope groove is then mechanically cut into the outer surface of the pipes manufactured in this way in order to be able to wind up the rope in a controlled manner.

As an alternative to such welding together of bent metal sheets, the drum shell can also be made from a drawn tube. In this way, however, only cable drums of limited dimensions can be produced, and usually only drum diameters of up to approx. 700 mm and wall thicknesses of up to approx. 50 mm can be produced in this way. Even with such drawn cable drum tubes, the cable grooves are usually machined into the outer surface.

Proceeding from this, the present invention is based on the object of creating an improved cable drum, an improved cable winch and an improved method for producing such a cable drum, which avoid the disadvantages of the prior art and develop the latter in an advantageous manner. In particular, a cable drum for large cable winches or heavy-duty winches that is easy to manufacture and withstands high pressure loads with sufficient safety is to be created, which is subject to fewer restrictions in terms of wall thicknesses, diameters and material than cable drums known to date.

According to the invention, the stated object is achieved by a production method according to claim 1, a cable drum according to claim 9 and a cable winch according to claim 14. Preferred developments of the invention are the subject matter of the dependent claims.

It is therefore proposed that the drum shell or cable drum tube should no longer be drawn or welded together from a bent sheet metal, but instead be manufactured seamlessly and smoothly from one piece by rolling. According to the invention the drum shell is seamlessly rolled from a ring-shaped workpiece blank. Said ring-shaped workpiece blank is formed into said drum shell with the required wall thickness and diameter by a rolling process. A rope groove profile is formed on the outer surface of the drum shell during and/or after it is rolled.

The above-mentioned cable groove profile on the outer surface of the seamless drum shell is formed without cutting by a tool that is formed in the outer surface. Advantageously, the cable groove profile can be produced by rolling or rolling by means of a rolling tool formed in the outer lateral surface, as is used in a similar way for thread rolling.

By rolling the drum shell of the cable winch and its non-cutting grooved cable profile, very large dimensions and unit weights can be realized without high device costs, with the drum diameter and wall thicknesses being essentially arbitrarily adapted to the desired construction. In particular, there are no special model or mold costs as with cast cable drums or device costs for dies and patrixes, as they are required for pipe drawing. On the other hand, joints and irregularities, such as those that occur when bent sheets are welded together, can be avoided and accordingly a better flow of forces and a more even stress distribution over the entire circumference of the drum shell can be achieved, so that a high level of resistance to pressure stress is achieved. In this regard, there is also the fact that, by dispensing with weld seams, there is no uneven heat input on the circumference of the drum shell, so that warping of the drum shell and the associated stresses can be avoided.

At the same time, the rolling process improves the mechanical and technological properties of the cable drum shell. In particular, structural defects such as a coarse or oriented structure, which is characteristic of pipe drawing, for example, or cavities that are present in the cast blanks due to production, can be eliminated by rolling. Rolling achieves a high degree of deformation and evens out the microstructure. In particular, a uniform, fine microstructure largely free of defects such as cavities can be achieved, which is significantly more uniform, finer and has fewer cavities compared to a cast or drawn cable drum.

In particular, the drum shell can also be made of non-weldable steels, since the rolling of the drum shell means that joints no longer have to be welded together. However, depending on the application, weldable steels can also be used and rolled to form the drum shell. All in all, rolling allows a wide variety of materials to be used.

In a development of the invention, the ring-shaped blank can be pressure-formed during rolling on the outer surface side with a main roller and a mandrel roller, which delimit a radial roll gap between them, while rotating the ring-shaped blank about a blank axis of rotation. The main and mandrel rollers mentioned can be placed towards one another by a feed drive or their distance from one another can be adjusted in order to be able to adjust the radial roller gap mentioned and to be able to apply the forming pressure required for the roll forming. At the same time, the desired wall thickness of the drum shell can be set by adjusting the radial roll gap mentioned.

In addition to the main and mandrel rolls mentioned, the annular blank can be pressure-formed on the face side by means of at least one pair of axial rolls which define an axial roll gap between them and form or reshape the end faces of the resulting drum shell.

Said axial rollers can be designed conically in order to delimit a V-shaped or wedge-shaped axial roller gap viewed in cross section.

A tangential material flow occurs as a result of the roll forming by means of the main and mandrel rolls mentioned as well as the axial rolls mentioned and the reduction in wall thickness and ring height that can be achieved as a result, as a result of which the ring diameter increases. In order to be able to avoid the ring diameter increase, the axial stand with the two axial or tapered rollers can be positioned radially along the longitudinal machine axis, which longitudinal machine axis can be formed by the axis of the main and mandrel rollers and the longitudinal axis of the axial rollers.

Said cable groove profile can optionally be reworked by machining. In particular, the cable groove profile can be cut or trimmed into the outer lateral surface by turning.

In an advantageous development of the invention, a climbing area for the rope to be wound is provided on the end sections of the drum shell, which climbing area allows the rope to rise into the next winding layer when or before it runs against the flanged wheel and lets it run back in the next winding layer. This rising area can advantageously be formed at the same time as the drum shell is rolled, so that no further production step is necessary. Alternatively, the mentioned riser area can be formed after the rolling of the casing body by further, subsequent non-cutting machining on the outer lateral surface, for example by a subsequent rolling and/or rolling step and/or another non-cutting forming step, by means of which the end section is formed at the edge to to form the ascent area.

As an alternative to such an integral, one-piece molding of the riser area onto the drum shell, however, the riser area can also be designed as a separate component, which is subsequently joined to the seamless drum shell. Advantageously, a joining surface can be formed on the seamless drum shell for such a separate step element, in particular during the rolling of the drum shell or possibly also in a further processing step following the rolling process.

The named end plates of the cable drum are advantageously formed separately and subsequently joined to the drum shell, for example screwed there.

The design of the drum shell in the form of a seamless, smooth rolled profile can be particularly advantageous in connection with large drum shell diameters of, for example, more than 0.75 m and wall thicknesses of more than 60 mm. In particular, the drum shell can also have a diameter of more than 1 m or even several meters. The wall thicknesses can also be significantly greater than the aforementioned 60 mm, for example more than 74 mm or more than 100 mm, with drum wall thicknesses of 150 mm or more being able to be manufactured.

Advantageously, the wall thickness of the drum shell can be significantly greater than the depth of the cable grooves in the outer shell surface. For example, if the drum shell has the aforementioned smooth inner surface, the wall thickness of the drum shell, measured between the smooth inner surface and the bottom of the cable grooves in the outer surface, which corresponds to a minimum wall thickness, can be more than 150% or more than 200% or even more than 300% or more than 400% of the depth of the rope grooves.

Fig. 1:

eine schematische Frontansicht einer Seilwinde mit einer Seiltrommel nach einer vorteilhaften Ausführung der Erfindung, wobei die Seiltrommel an einem Windenrahmen drehbar gelagert ist und ein Antriebsgetriebe im Inneren der Seiltrommel aufgenommen ist,

Fig. 2:

eine schematische Schnittansicht des Trommelmantels der Seiltrommel aus Fig. 1,

Fig. 3:

eine schematische Darstellung einer Walzvorrichtung zum Walzen des Trommelmantels der Seiltrommel aus den vorhergehenden Figuren, wobei die radiale und axiale Beaufschlagung eines rotierenden, ringförmigen Werkstückrohlings durch Haupt- und Dornwalzen sowie ein Paar Axialwalzen dargestellt ist,

Fig. 4:

eine weitere Ansicht des Trommelmantels der Seiltrommel aus den vorhergehenden Figuren, wobei die Teilansicht a eine Draufsicht auf die Außenmantelfläche des Trommelmantels ist und dessen endseitige Aufstiegsbereiche zeigt, die Teilansicht b eine Schnittansicht entlang der Linie A-A in der Teilansicht a ist und die Konturierung des Aufstiegsbereichs in Umfangsrichtung des Trommelmantels zeigt, wobei ferner die Teilansicht c eine ausschnittsweise, vergrößerte Darstellung des genannten Aufstiegsbereichs ist und die Teilansicht d eine ausschnittsweise, vergrößerte Schnittansicht des Trommelmantels ist, die das Verhältnis der Tiefe des Seilrillenprofils zur Wandstärke des Trommelmantels verdeutlicht, und

Fig. 5:

eine ausschnittsweise vergrößerte Darstellung des Aufstiegsbereichs des Trommelmantels ähnlich der Teilansicht c der Figur 4, wobei der Aufstiegsbereich nach einer weiteren Ausführung der Erfindung als separates, nachträglich auf den Trommelmantel gefügtes Bauteil ausgebildet ist.

The invention is explained in more detail below using a preferred exemplary embodiment and associated drawings. In the drawings show:

Figure 1:

a schematic front view of a cable winch with a cable drum according to an advantageous embodiment of the invention, wherein the cable drum is rotatably mounted on a winch frame and a drive gear is accommodated inside the cable drum,

Figure 2:

a schematic sectional view of the drum shell of the cable drum 1 ,

Figure 3:

a schematic representation of a rolling device for rolling the drum shell of the cable drum from the previous figures, wherein the radial and axial loading of a rotating, ring-shaped workpiece blank is represented by main and mandrel rollers and a pair of axial rollers,

Figure 4:

another view of the drum shell of the cable drum from the previous figures, with partial view a being a plan view of the outer surface of the drum shell and showing its end-side rise areas, partial view b being a sectional view along line AA in partial view a and the contouring of the rise area in Circumferential direction of the drum shell, with the partial view c also being a sectional, enlarged view of the named rise area and the partial view d being a sectional, enlarged sectional view of the drum shell, which illustrates the relationship between the depth of the cable groove profile and the wall thickness of the drum shell, and

Figure 5:

a sectional enlarged view of the rise area of the drum shell similar to the partial view c of figure 4 , wherein according to a further embodiment of the invention, the riser area is designed as a separate component which is subsequently joined to the drum shell.

How 1 shows, the cable winch 1 comprises a cable drum 2, which has an at least approximately cylindrical drum shell 3 and two end plates 4, which extend transversely to the longitudinal axis 5 of the drum shell 3, connect to the drum shell 3 at the front and protrude radially beyond the drum shell 3 in order to To limit the winding space 6 laterally over the outer circumference of the drum shell 3 .

Said end disks 4 are rigidly fastened to drum shell 3, in particular on the front side, with said end disks 4 advantageously being formed separately from drum shell 3 and being fastened to it in a positive and/or non-positive manner, for example by means of screw bolts 7, by means of which end disks 4 are attached to the Faces of the drum shell 3 can be screwed.

Said cable drum 2 can be rotatably mounted on a winch frame 8, with the end plates 4 advantageously having bearing sections 9, by means of which the cable drum 2 is rotatably mounted on the winch frame 8, for example by means of roller bearings 10.

To drive the cable drum 2, the cable winch 1 can have a drive gear 11, which can be accommodated at least partially inside the cable drum 2 and/or can extend through one of the end plates 4. Said drive gear 11 can, for example, be a single-stage or multi-stage planetary gear.

A winch drive, for example in the form of a hydraulic motor or an electric motor, can be connected to said drive gear 11 in order to be able to drive the cable drum 2 in rotation about the longitudinal axis 5 of the drum shell 3 and/or to provide a desired braking torque when the cable is pulled off the cable drum 2 can, for which purpose a suitable braking device can also be provided.

The cable drum 2 can be designed with very large dimensions, for example a diameter of several meters and/or a drum wall thickness of 100 mm and more, possibly also several hundred millimeters.

As the figures 2 and 3 show, the drum shell 3 of the cable drum 2 is designed as a seamless, impact-free rolled section that can be produced by rolling an annular workpiece blank 12 . The rolling device 13 can be designed in the manner of a ring rolling mill and/or advantageously have a main roll 14 and a mandrel roll 15, which delimit a radial roll gap 16 between them, the gap width of which can be adjusted, for example, by adjusting the mandrel roll 15. By advancing the mandrel roller 15 towards the main roller 14, the workpiece blank 12, which is sometimes also referred to as a blank tube, can be pressurized on the lateral surface side and formed. One of the rollers mentioned, for example the main roller 14, can be driven in rotation so that the ring-shaped workpiece blank 12 rotates through the radial roller gap 16 and rotates about its workpiece axis of rotation while the rolling process is being carried out. If necessary, the mandrel roller 15 can also be driven as an alternative or in addition to the main roller 14 mentioned.

The workpiece blank 12 can originally be an already one-piece cast blank, which can already be ring-shaped or can be provided with a hole or ring-shaped by means of a mandrel rolling and/or forging step.

Said main and mandrel rolls 14 and 15 can be essentially cylindrical and arranged parallel to one another, so that the radial roll gap 16 has an essentially constant gap width over its height.

In addition to the mentioned main and mandrel rolls 14 and 15, the workpiece blank 12 can be rolled during the rolling process by at least one pair Axial rollers 17 are acted upon at the ends in order to be able to shape or reshape the end faces of the drum shell 2 that is being formed.

The axial rollers 17 and 18 mentioned can each be conical and taper towards the center of the ring-shaped workpiece blank 12, it being possible for the two axial rollers 17 and 18 to be arranged with their axes of rotation in a common plane which is defined by the two aforementioned mandrel and main rollers 14 and 15 can go. In other words, the pair of axial rollers 17, 18 can lie opposite the main and mandrel rollers 14 and 15 or act on a ring section of the workpiece blank 12 which lies opposite the ring section acted upon by the mandrel and main rollers.

At least one of the two axial rollers 17 and 18 can be adjusted in the axial direction towards the other axial roller in order to be able to apply pressure to the end faces of the workpiece blank 12 . At the same time, the resulting length of the drum shell can be controlled by adjusting the spacing of the axial rollers 17, 18 from one another.

After the drum shell 3 has been rolled, ie the workpiece blank 12 has been formed by rolling towards the drum shell 3 or during the rolling itself, a cable groove profile 19 can be formed on the outer surface 3a of the drum shell 3, such as this 3 shows. Said grooved rope profile 19 can be formed by non-cutting forming, for example by a rolling tool that is reflected in the outer lateral surface and forms the grooved rope profile mentioned, similar to thread rolling.

How figure 4 shows, in particular its partial views a to c, a climbing area 19a can be formed on the end sections of the drum shell 3, which rises continuously viewed in the circumferential direction, cf. partial view 4b, in order to let the rope running on it rise and let it run back in the next winding layer .

Said rise area 19a can advantageously also be formed during the rolling of drum shell 3, so that said rise area 19 is formed integrally in one piece on drum shell 3 and is formed by a section of the seamlessly formed rolled profile.

In particular, the mentioned ascent area 19a can connect seamlessly and/or without jumps to the rope groove profile 19, so that the rope running in the last rope groove runs harmoniously onto the ascent area 19a and is lifted to the next winding layer by its incline in the circumferential direction of the drum shell.

How figure 5 shows, the above-mentioned riser area 19a can also be designed as a separate element, which is subsequently attached to the seamlessly rolled drum shell 3. Said separate part can form the entire riser area 19a or just a section thereof.

Advantageously, the separate ascent part sits on the outer surface of the drum shell 3, wherein the drum shell 3 can have a suitably designed joining surface, in particular a ring or partial ring surface on the outer shell, to which the riser area can be joined. Advantageously, the drum shell can also have a frontal contact surface for the mentioned riser area, in order to prevent the separate element from being pushed away to the side, cf. figure 5 .

The joining surface formed on the drum shell 3 for the separate rising element can be formed on the drum shell without cutting, in particular it can also be formed during rolling.

Like the partial view d the figure 4 shows, the wall thickness of the drum shell 3 can be significantly greater than the depth of the rope grooves of the rope groove profile 19. The minimum wall thickness x, measured from the smooth inner surface to the bottom of the rope grooves, can be, for example, more than 200% or more than 300% of the depth y - x of the rope grooves are 19.

The contour of the inner lateral surface can deviate from the rope groove profiled contour of the outer lateral surface and does not have to follow it. In particular, the inner lateral surface of the drum casing 3 can be smooth, in particular at least approximately cylindrical.

Claims (15)

1. A method of manufacturing a rope drum (2) that has a drum casing (3) and end plates (4) attached thereto at the end faces, characterized in that the drum casing (3) is seamlessly rolled from an annular workpiece blank (12) by means of a rolling apparatus (13), with a rope groove profile (19) being formed at the outer casing surface (3a) of the seamless drum casing (3) on and/or after the rolling thereof by a non-cutting machining by means of a tool that is mapped in the outer casing surface (3a).
2. A method in accordance with the preceding claim, wherein the rope groove profile is formed at the outer casing surface (3a) of the drum casing (3) by rolling by means of a rolling tool that is mapped in the outer casing surface (3a).
3. A method in accordance with one of the preceding claims, wherein an inner casing surface of the drum casing (3) is formed as smooth and/or as without a groove profile and is in particular rolled smooth so that the wall thickness of the drum casing (3) becomes cyclically thinner and thicker again viewed in cross-section between the smooth inner casing surface (3i) and the outer casing surface (3a) having the groove profile.
4. A method in accordance with one of the preceding claims, wherein a rising region (19) for the rope to be wound is formed by the rolling process at at least one end section of the drum casing (3) at its outer casing surface (3a).
5. A method in accordance with one of the preceding claims, wherein the rising region (19a) for the rope to be wound is joined as a separate part after the rolling process to a section of the drum casing (3) rolled for this purpose, with a joint surface preferably being formed by the rolling procedure at the drum casing for joining the rising region.
6. A method in accordance with one of the preceding claims, wherein the annular workpiece blank (12) is pressure shaped at the casing surface side by a main roll (14) and by a mandrel roll (15) that bound a radial roll gap (16) between them while rotating the annular workpiece blank (12) about a blank axis of rotation; wherein the annular workpiece blank (12) is additionally pressure shaped at the end face side between at least one pair of axial rolls (17, 18) that bound an axial roll gap between them; and wherein conical axial rolls (17, 18) are used that taper toward a center of the workpiece blank (12) and are arranged in a common plane that passes through the main and mandrel rolls (14, 15).
7. A method in accordance with one of the preceding claims, wherein the end plates (4) are formed separately and are subsequently joined, in particular screwed, to the drum casing (3).
8. A method in accordance with one of the preceding claims, wherein the annular workpiece blank (12) is provided as a cast blank or is shaped in a mandrel roll step and/or a forge step from an initially hole-less blank.
9. A rope drum for winding and unwinding a rope, comprising a drum casing (3) to whose end faces end plates (4) are fastened, characterized in that the drum casing (3) is formed in the shape of a seamless, joint-free roll profile having a rope groove profile (19) in the outer casing surface (3a) imparted in a non-cutting manner.
10. A rope drum in accordance with the preceding claim, wherein an inner casing surface of the drum casing (3) is smooth, without a groove profile, so that the wall thickness of the drum casing cyclically increases and decreases again viewed in a transverse longitudinal section between the smooth inner casing surface and the grooved outer casing surface; and wherein the maximum depth of the rope grooves at the outer casing surface amounts to less than 50% of the minimal wall thickness of the drum casing (3).
11. A rope drum in accordance with one of the preceding claims, wherein a rising region (19) for the rope to be wound is formed in the shape of a roll profile surface formed in a non-cutting manner at at least one end section of the drum casing (3).
12. A rope drum in accordance with one of the preceding claims, wherein a rising region (19) for the rope to be wound is provided at at least one end section of the drum casing (3) in the form of a separate component that is joined to the drum casing (3); and wherein the drum casing (3) has a diameter of more than 0.75 m or more than 1 m or more than 3 m; and/or has a casing wall thickness of more than 75 mm or more than 100 mm or more than 150 mm.
13. A rope drum in accordance with one of the preceding claims, wherein the drum casing (3) comprises non-weldable steel; and wherein the drum casing (3) has a fine grained matrix structure that is substantially free of shrinkage cavities and has a high degree of shaping.
14. A rope winch comprising a rope drum that is configured in accordance with one of the claims 9 to 13 and that is rotatably supported at a winch frame (8).
15. A rope winch in accordance with the preceding claim, wherein the rope drum (2) is connected to a drive transmission (11) that is at least partially received in the interior of the rope drum (2).

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