1、iC 621.8W.87 : 621.854 : 677.72 DEUTSCHE NORM Februaty 1974 DIN Lifting Appliances 15 020 Principles Relating to Rope Drives Part 1 Calculation and Construction Hebezeuge; Grundstze fr Seiltriebe; Berechnung und Ausfuhrung 4s it is current practice in standards published by the International Organiz
2、ation for Standardization (ISO), the iomma has been used throughout as a decimal marker. This Standard incorporates technical safety stipulations within the meaning of the Law on Technical Equipment, ree Explanations. This Standard has been drawn up in collaboration with the Hauptverband der gewerbl
3、ichen Berufsgenossenschaften, Zentralstelle fur Unfallverhutung (Federation of Industrial Injuries Insurance Associations, Central Office for Accident Prevention), Bonn, and with the Bundemerband der landwirtschaftlichen Berufsgenossenschaften, Hauptstelle fur landwirtschaftliche Unfallverhutung (Fe
4、deral Association of Agricultural Injuries Insurance Associations, Central Office for Accident Prevention in Agriculture), Kassel. For connection with publications of the Fdration Europenne de la Manutention( FEM = European Mechanical Handling and Conveying Technology Federation), see Explanations.
5、Contents Page 1 scope 2 2 Purpose 2 3 Concepts -2 Calculation of rope drive .2 (coefficient c) .2 4 4.1 Mode of operation (drive group) .2 4.2 Calculation of rope diameter 4.3 Calculation of the diameters of rope drums, rope pulleys and com ensating pulleys coefficient (hl . h2)f. .4 4.4 Dimensionin
6、g of the rope groove (ratio of groove radius to rope diameter) .5 5.1 Nominal strength of the wires . .5 5.2 Wire diameter .7 5.3 Number of strands . .7 5.4 Type of stranding of the strands .7 5.5 Type of lay. . .7 5.6 Handoflay . .7 5.7 Non-twistingornon-rotating wireropes . .7 5.8 Low stress wire
7、ropes . .7 5.9 Steel core . .7 5 Wireropes .5 Page 5.10 Galvanizing. . 7 5.11 Lubrication of the wire rope 7 5.12 Length deviation 7 5.14 Laying of the wire ropes . 7 5.13 Marking 7 6 6.1 Condition of the rope end . 7 6.2 Additional stresses in the rope 7 6.3 Construction of components . 7 6.4 Stres
8、sing of components 8 6.5 Maintenance facility . 8 7 Further requirementsrelating to rope drives 8 7.1 Number of safety turns .8 7.3 Safeguard against running off . 8 7.4 Contact with stationary structural components . . 8 7.5 Exposure to heat .8 7.6 Drumdmensions .8 7.7 Protective casings for rope p
9、ulleys and compensating pulleys . 8 Rope suspensions and rope attachments . 7 7.2 Sideways deflection . 8 Appendix: Efficiency of rope drives . .9 See DIN 15 020 Part 2 (new edition, at present still in draft form) for principles relating to rope drives, supervision during service. See DIN 15 018 Pa
10、rt 1, draft February 1967 edition, Section 8, for holding ropes and tensioning ropes See DIN 15 O60 for sling ropes Continued on pages 2 to 9 Explanations on pages 10 to 12 Sole sala right. of Qennan Stan in the case of rope drives for vehicle winches, an increase in traction force of up to 15% of t
11、he nominal traction force for horizontal traction or for traction at an incline up to 45O, on condition that a safeguard against overloading has been incorporated. If the case of rope drives for multiple rope grabs and similar load suspension devices, the load is not always uniformly distributed bet
12、ween the grab closing rope($ and the holding rope(s) during a working cycle. For this reason, the following distribution of the load onto the closing rope(s) and the holding rope($ is recommended: If the system used promptly and automatically ensures the uniform distribution of the load onto the clo
13、sing rope(s) and holding rope($: Closing rope(s) and holding rope($: 66 % of the load each If the system used does not ensure the uniform distribution of the load onto the closing rope(s) and the holding rope(s) during the course of the lifting process: Closing rope(s): 100% of the load Holding rope
14、(: 66% of the load 4.3 Calculation of the diameters of rope drums, rope pulleys and com ensating pulleys coefficient (hl . h2)f The diameter D of rope drums, rope pulleys and com- pensating pulleys, related to the centre of the wire rope, is calculated from the minimum rope diameter d- determined ac
15、cording to Section 4.2, in accordance with the formula below: the factor h2 is dependent on the arrangement of the rope drive and is listed in Table 5. The values adopted may be lower than those listed in the tables in the case of run-in devices for vehicle winches and of transfer rollers on timber
16、trucks, if this becomes necessary for design or operational reasons. I 5, I 25 I 28 I 28 I 31.5 I 18 I 20 Rope pulleys in grabs may be sized in accordance with drive group 1 B, independently of the grading of the remainder of the rope drive. I 6) In the case of serial lifting appliances, the same co
17、efficients hl may be used for non-twisting or non-rotating wire ropes as for wire ropes which are not non-twisting, on condition that an adequate sewice life is achieved by virtue of the selection of the rope design. DIN 15020 Part 1 Page 5 opposite direction, a 5“ : Rope pulley, a S 5O (see Fig. 2)
18、 Compensating pulley: End attachment of rope: I i w-4 w-o o _- Figure 3. Deflection in the same direction Deflection in the opposite direction Nominal groove radii have been allotted in Table 6 to the nominal rope diameters. Permissible deviations for the groove radius shall be in accordance with DI
19、N 15 061 (at present stili in draft form). Deflection in the opposite direction must be taken into consideration if the angle between the planes of two adjacent rope pulleys (traversed by the rope in succession) amounts to more than 120 (see Fig. 3). (See page 6 for Table 5) 4.4 Dimensioning of the
20、rope grooves (ratio of groove radius to rope diameter) The service life of a wire rope increases with decreasing squeeze between the wire rope and the grooves. It is, therefore, recommended to match the groove radius r as favourably as possible to the nominal diameter d of the rope laid in the .groo
21、ve. The minimum recommended value for r is: r = 0,525 - d (4). 5 Wireropes 5.1 Nominal strength of the whs This Standard applies to wire ropes made of steel wires according to DIN 2078, of 1570,1770 and 1960 N/mm2 (160,180 and 220 kp/mm2) nominal strength, and also, in the case of conventional trans
22、ports, to wire ropes which are not non-twisting and which are made of steel wires of 2160 and 2450 N/mmz (220 and 250 kp/mm2) nominal strength (at present not yet standardized). Page 6 DIN 15020 Part 1 Table 5. Coefficients h2 Examples for arrangements of rope drives h27) for ipednims, ompensn- ring
23、 pulleys Examples of application (drums illustrated in double lines) W Description “ire rope runs on rope irum and over no more ;han 2 rope pulleys with deflection in the same direction or 1 rope pulley with deflection in opposite direction UP to 5 1 / Q Wire rope runs on rope irum and over no more
24、than 4 rope pulleys with deflection in the same direction or 2 rope pulleys with deflection in the same direction and 1 rope pulley with deflection in the opposite direction or 2 rope pulleys with deflection in the opposite direction *I w=7 6 ip to 9 10 and over 1 w=7 2 pulley blocks eachw=7 x s Wir
25、e rope runs on rope drum and over at least 5 rope pulleys with deflection in the same direction 3 rope pulleys with deflection in the same direction plus 1 rope pulley with deflection in the opposite direction or 1 rope pulley with deflection in the same direction plus 2 rope pulleys with deflection
26、 in the opposite direction 3 rope pulleys with deflection in the opposite direction Or O1 . u !I! i/ I s *I b I i 1 2pulley blocks each w= 11 w=13 . , independently of For rope pulleys in serial lifting appliances and grabs, h2 can be assumed at a value of h2 = the arrangement of the rope drive. *)
27、Compensating pulley 7) The correlation of w and h2 in respect of the discription and of the examples of application is only valid on condition that o n e segment of rope runs through the entire arrangement of the rope drive during one working stroke. For the determination of hp, only the values of w
28、 which occur at the most unfavourable segment of the rope need be considered. DIN 15020 Part 1 Page 7 5.2 Wirediameter In so far as the wire ropes are exposed to mechanical damage, heavy external abrasive wear or strong corrosive attack, rope designs with thick outer wires are advantageous. 5.3 Numb
29、er of strands Wire ropes with a large number of strands (e.g. 8 strands) exhibit a more closed surface and, therefore, exert a lower squeeze in the rope groove than wire ropes with a smaller number of strands (e.g. 6 strands). 5.4 Type of stranding of the strands In the case of wire ropes with stran
30、ds arranged in parallel stranding (with equal lengths of lay of the wires in the strand layers, e.g. Seale, Warrington or Filler types), the reciprocal pressing action of the wires is less than in the case of wire ropes with an equal lay angle of the wires in all the layers of the strands. In the la
31、tter arrangement, the wires of superimposed wire layers cross over one another. Parailel lay ropes, therefore, usually achieve a longer service life and are better suited for drive groups with heavy duty operation than are wire ropes made from strands with an equal lay angle in all the wire layers.
32、5.5 Type of lay Crossiay ropes are generally used for rope drives. Longer service lives can be achieved with long lay ropes. It must, however, be borne in mind that the loading of long lay ropes generates a greater torque than the equiva- lent loading of crosslay ropes. 5.6 Handoflay In the case of
33、grabs with closing ropes and holding ropes arranged in pairs, and also in the case of other load suspension devices suspended in similar fashion, an equal number of wire ropes of the same type must be used in each case, half of which must be right-hand lay and the other half left-hand lay. It is rec
34、ommended to lay wire ropes with a right-hand lay of the outer strands on rope drums with a left-handed pitch of the rope grooves, and vice-versa. 5.7 Non-twisting or non-rotating wire ropes if the load is suspended on o n e ply only and is not guided, then non-twisting or non-rotating wire ropes mus
35、t be used. If the hoisting height is considerable md the load is not guided, non-twisting or non-rotating wire ropes shall also be used in the case of multi-ply suspension, unless the twisting together of the rope strands can be prevented by structural or design means. 5.8 Low stress wire ropes Wire
36、 ropes with low stress stranding have the advantage of exhibiting either no or only very little elastic recoil of the stranded wires, and also that the wires and strands will not fly apart, or only fly apart to a limited extent, when the rope is cut. They are easier to handle for laying. Long lay ro
37、pes should only be used in the low stress stranding form. 5.9 Steelcore The calculation in accordance with Section 4 also applies to wire ropes with steel core. 5.10 Galvanizing If there is any risk of corrosion, the use of galvanized wire ropes is recommended, e.g. in the case of maritime climates,
38、 of operation in aggressive media, and in the case of wire ropes which lie in the open air for prolonged periods 5.11 Lubrication of the wire rope Lubricants in the wire rope diminish friction, both between the groove and the wire rope, and between the individual wires of the wire rope; in addition,
39、 corrosion is reduced. If the lubrication of the wire rope has to be dispensed with for operational reasons, one must reckon with a shorter service life of the rope. The use of non-lubricated wire ropes must be specially agreed. 5.12 Length deviation In the case of wire ropes supplied in factory len
40、gths ready for use, the length deviation must be agreed, and + 1 % is recommended for this purpose. If several wire ropes of the same length are required for use on o n e lifting gear or one load suspension device, then the length deviation between the several wire ropes must not exceed 0,2 %. 5.13
41、Marking The marking of wire ropes supplied in factory lengths ready for use must be agreed. 5.14 Laying of the wire ropes When pulling the wire rope off the reel or when uncoiling it from a coil, and when mounting it into the rope drive, make sure that the wire rope is neither untwisted nor twisted
42、more tightly. If the wire rope is liable to drag over sharp-edged structural components in the unloaded state, then such components must be covered. Before commissioning, make sure that the wire rope is correctly reeved, and that it seats properly in the grooves of rope drums, rope pulleys and compe
43、nsating pulleys. 6 Rope suspensions and rope attachments 6.1 Condition of the rope end The rope end must be of such a condition that a durable guarantee exists that the rope structure will not become slack in time (e.g. by flash butt welding or by serving with wire), inasmuch as the rope bond is not
44、 unravelled by the nature of the rope attachment (e.g. in the case of splicing or sweating). 6.2 Additional stresses in the rope Rope flexures and other additional stresses of the wire rope in the region of the rope suspension must be avoided. The rope suspension, in the case of wire ropes which are
45、 not non-twisting, must be designed in such a way that rotations of the wire rope about its longitudinal axis cannot take place. In the case of non-twisting or non- rotating wire ropes, the end attachment may permit rotations of the wire rope about its longitudinal axis. 6.3 Construction of componen
46、ts Rope suspensions must not be effected by means of roller thimbles. Rope eyes must be provided either with solid thimbles (standardization at present in preparation) or with thimbles of shape B or C in accordance with DIN 6899. Where rope clamps of aluminium flat oval tubing are used in rope suspe
47、nsions, then the standard at present in preparation must be complied with in respect of the blanks, the compression joint and the manufacture. Splicings used for rope suspensions must be executed in Page 8 DIN 15020 Part 1 accordance with DIN 83 318 with at least 6 1/2 circum- ferential tucks: Splic
48、es on wire ropes for single ply operation must be executed “against the hand of lay”; this splice execution must be agreed at the time of placing the purchase order. The splice must not be jacketed, so that it can be inspected during operation. 6.4 Stressing of components Rope suspensions must be di
49、mensioned in such a way that they are able to absorb 2,5 ties the rope traction force without any permanent deformation. If a rope socket is used, the free rope end must be secured against pull through even if a self-locking rope wedge is incorporated. This safety device must be capable of absorbing 10% of the rope traction force. No devices which involve the connection of the free rope end to the load carrying rope ply with a positive transmission of force may be used as safety devices. The rope attachment onto the rope drum must be designed in such a way that 2,5 times the rop
