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1、BRITISH STANDARD BS 7035:1989 Code of practice for Socketing of stranded steel wire ropes UDC 677.721:62229.211.6034:669.5412:669.14427.4:001.4:620.1:(083.75) Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS
2、7035:1989 This British Standard, having been prepared under the direction of the Mechanical Handling Standards Committee, was published under the authority of the Board of BSI and comes into effect on 31 May 1989 BSI 02-1999 The following BSI references relate to the work on this standard: Committee
3、 reference MHE/2 Draft for comment 87/72078 DC ISBN 0 580 17025 X Committees responsible for this British Standard The preparation of this British Standard was entrusted by the Mechanical Handling Standards Committee (MHE/-) to Technical Committee MHE/2, upon which the following bodies were represen
4、ted: Associated Offices Technical Committee Association of Supervisory and Executive Engineers British Coal Corporation British Ports Association and the National Association of Ports Employers British Steel Industry (Wire Section) Bureau Veritas Chain Testers Association of Great Britain Department
5、 of the Environment (Property Services Agency) Federation of Manufacturers of Construction Equipment and Cranes Federation of Wire Rope Manufacturers of Great Britain Health and Safety Executive Institution of Mechanical Engineers Institution of Mining Engineers Institution of Mining and Metallurgy
6、Lloyds Register of Shipping Ministry of Defence National Association of Lift Makers Zinc Development Association Amendments issued since publication Amd. No.Date of issueComments Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Uncontroll
7、ed Copy, (c) BSI BS 7035:1989 BSI 02-1999i Contents Page Committees responsibleInside front cover Forewordii 1Scope1 2Definitions1 3Preparation of rope and socket1 4Resin socketing4 5Metal socketing4 6Inspection5 Appendix A Prototype qualifying tests on socketing materials6 Appendix B In-service ins
8、pection advice6 Appendix C Flow chart presentation of socketing procedures for stranded steel wire ropes7 Figure 1 Nomenclature of parts of sockets2 Figure 2 Location of permanent serving2 Figure 3 Brush3 Figure 4 Socketing procedure flow chart7 Table 1 Reference test forces6 Table 2 Test rope selec
9、tion6 Publications referred toInside back cover Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7035:1989 ii BSI 02-1999 Foreword This British Standard has been prepared under the direction of the Mechanical
10、 Handling Standards Committee. The integrity of socketed terminations of ropes relies on the skilled application of proved and accepted procedures. Termination failures can often be attributed to poor socketing and the committee responsible for steel wire ropes has identified the need for a code of
11、practice setting down the procedures necessary to ensure efficient and effective socketed terminations. This British Standard aligns with ISO 7595 and ISO/TR 7596 but omits certain practices not used in the UK. A British Standard does not purport to include all the necessary provisions of a contract
12、. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 8, an inside back cover
13、and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Unco
14、ntrolled Copy, (c) BSI BS 7035:1989 BSI 02-19991 1 Scope This British Standard gives guidance on recommended practices for resin and metal (white metal or zinc) socketing of wire ropes complying with BS 302-1 to BS 302-8 and using sockets complying with BS 4631), for use within service temperature l
15、imitations of 20 C to + 70 C. Appendix A gives tests on socketing materials. In-service inspection advice is given in Appendix B. Appendix C contains a socketing procedures flow chart. NOTE 1The code is generally applicable also to the socketing of other wire ropes and using other sockets, but speci
16、al precautions may be necessary and the ropes supplier should be consulted. NOTE 2When socketing ropes which have wire tensile grades greater than 1 960 N/mm2 special precautions may be necessary and the ropes supplier should be consulted. NOTE 3The titles of the publications referred to in this sta
17、ndard are listed on the inside back cover. 2 Definitions For the purposes of this British Standard, the definitions given in BS 302-1 apply, together with the following. The nomenclature for parts of sockets are given in Figure 1. 2.1 sponsor the person or organization which takes responsibility for
18、 a particular socketing system. In particular he takes responsibility for the socketing material, identification, prototype testing (except where metal complying with BS 643 and BS 3436 is used) and the specification and method of application 2.2 coarse construction rope rope having eight strands or
19、 less and strands with one layer of wires over a king wire 3 Preparation of rope and socket 3.1 General NOTE3.1.1 to 3.1.8 should be read before the procedures in 3.2 are carried out. 3.1.1 Serving. In this standard two types of serving are recognized and are designated temporary2) and permanent. Te
20、mporary servings should be used when cutting ropes and spiral strands; however, they are not always necessary when cutting preformed ropes. When used, the temporary servings should be applied to the rope on each side of the cut and need to hold the strands and wires in position during the cutting op
21、eration. Permanent servings are applied to that part of the rope which is partly within or adjacent to the neck of the socket when the operation is completed (see Figure 2). A permanent serving should: a) ensure that the wires and strands are undisturbed during socketing operations; and b) permit th
22、e passage of the served rope through the neck of the socket. 3.1.2 Permanent serving material. Tinned or galvanized soft wire should be used except in the case of bright wire rope when bright wire may also be used. The diameter of the serving wire should be selected so that the served rope can be pa
23、ssed through the neck or small end of the socket with a radial clearance between the serving wire and the parallel part of the neck. Alternative material to the above may be used but care should be taken that it does not cause detrimental electrolytic action in service and that it is capable of with
24、standing the socketing temperatures involved. Copper and brass wires should not be used. Plastics of proven suitability may be used. 1) Under revision. 2) Temporary serving is synonymous with whipping. Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT
25、+00:00 2006, Uncontrolled Copy, (c) BSI BS 7035:1989 2 BSI 02-1999 Figure 1 Nomenclature of parts of sockets Figure 2 Location of permanent serving Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7035:1989 B
26、SI 02-19993 3.1.3 Cutting the rope. The rope should be cut by any suitable method which does not disturb the position of the wires under the permanent serving. Cutting with an abrasive wheel is preferred. When cut by percussive or shearing methods special care is required to avoid disturbance of the
27、 rope configuration. 3.1.4 Forming the brush. Care should be taken when forming the brush not to bend the wires or strands to an excessive angle at the permanent serving since this may cause premature failure in a completed assembly (see Figure 3). On opening the strands no attempt should be made to
28、 straighten the wires. 3.1.5 Degreasing. The brush should be degreased to remove all traces of rope lubricant. Degreasing may be either by liquid or vapour methods. When using liquid degreasing agents the brush should be held downwards to prevent the degreasing fluid, or water, being trapped in the
29、throat of the brush. The degreasing process may be accelerated by the use of an ultrasonic device. Liquid degreasing agents should be liberally used and worked well into the throat of the brush. Care should be taken to ensure that the degreasing is confined to the brush and does not affect the rope
30、beyond the brush. It is essential to ensure that rope lubricant does not seep from beneath the permanent serving to contaminate the degreased areas prior to pouring. If water soluble liquid degreasing agents are used, the residue should be completely removed by washing off in boiling water. It is es
31、sential to ensure that the degreasing agent is completely removed and the brush is dried quickly and completely before pouring. Neither petrol nor paraffin should be used for degreasing. When using a vapour degreasing agent, special care needs to be taken to ensure that degreasing is confined to the
32、 brush and does not affect the rope beyond the brush. Chlorinated hydrocarbons and other toxic or flammable organic solvents should only be used in areas designed for the purpose or in an extremely well-ventilated environment. 3.1.6 Hooking. In general, hooking of wire ends is not recommended but ma
33、y be considered for coarse construction ropes used under impulsive loading. The length of the hooked portion should not be such that it impedes the flow of resin or molten metal during socketing nor significantly reduces the effective length of embedded wire. 3.1.7 Position of wires in socket. The w
34、ires at the large end of the socket should be reasonably well distributed and care should be taken to prevent appreciable lengths of the outer wires from bearing against the socket wall as this reduces the efficiency of the assembly. 3.1.8 Cores. When a rope contains a steel core the wires of the co
35、re should be completely unlaid to form an open brush. When a rope contains a fibre core the core should be cut back into the throat as far as possible. Ropes having man-made fibre cores should preferably be socketed using resin. 3.2 Preparation procedures 3.2.1 Ensure that the socket body selected i
36、s fit for its purpose. It should comply with BS 463 and should be clean and free from defects. 3.2.2 Select rope, measure and mark for cutting. 3.2.3 Clean the length of the rope to be threaded through the socket. A clean dry cloth or cloth dipped in solvent may be used. 3.2.4 Apply temporary servin
37、g on either side of the cutting mark if necessary. 3.2.5 Cut the rope (see 3.1.3). 3.2.6 Apply a length of permanent serving equal to two rope diameters (see Figure 2). 3.2.7 Remove all dirt, grease and scale from the inside of the socket basket. 3.2.8 Thread the cut end of the rope through the sock
38、et, taking care that the basket walls do not come into contact with the uncleaned part of the rope. 3.2.9 Remove the temporary serving at the point of cut and unlay the strands as far back as the permanent serving. 3.2.10 Open up the strands as shown in Figure 3 and described in 3.1.8. 3.2.11 Open o
39、ut the wires and hook if necessary. Figure 3 Brush Licensed Copy: London South Bank University, London South Bank University, Fri Dec 08 12:59:40 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 7035:1989 4 BSI 02-1999 3.2.12 Degrease the open brush (see 3.1.5). 3.2.13 If considered necessary, due to e
40、nvisaged difficulty in drawing a socket into position over a brush, place a turn of wire around the brush near its top end to draw the brush slightly together to a form approximating to, or slightly smaller than, the shape of the socket basket. 3.2.14 Draw the socket basket over the brush until the
41、ends of the wires (or bends if wires are hooked (see 3.1.6) are 1 mm to 2 mm above the basket of the socket. 3.2.15 Check that the wires are, as far as possible, evenly distributed at the top of the socket basket after removing the turn of wire, and that only minimum lengths of the outer wires are i
42、n contact with the basket wall (see 3.1.7). 3.2.16 Clamp the rope in a suitable support and align the axes of rope and socket. The rope below the socket should be straight for at least 30 rope diameters. 3.2.17 Seal the neck of the socket with suitable material or apply a centralizing gland to preve
43、nt leakage of the socketing material. Care should be taken to ensure that the sealing material is not pushed into the gap between the socket and the rope. 3.2.18 Follow the procedures in clause 4 for resin socketing, or clause 5 for molten metal socketing. 4 Resin socketing 4.1 General NOTE4.1.1 to
44、4.1.3 should be read before the procedures in 4.2 are carried out. 4.1.1 Resin systems. Resin systems are in general use and are mainly based on polyesters. These systems may vary considerably and it is essential to refer to the sponsors instructions before using them. Resin systems cure more slowly
45、 at low temperatures and if the ambient or socket temperature at the time of socketing is at, or below, 8 C the manufacturers special recommendations should be followed. The sponsor should provide adequate information on the use of his resin socketing system. This will include the following: a) uppe
46、r and lower socketing temperature; b) upper and lower service temperature; c) storage temperature. The resin systems used should be of the thermosetting type and have passed the qualifying tests given in Appendix A. Care should be taken that any resin packs used are sealed and are not out of date. 4
47、.1.2 Pouring. Resin systems should be mixed in suitable clean containers which do not react with the components. Polystyrene containers should not be used. The resin system should be poured immediately after mixing. Sufficient resin has to be mixed to ensure the complete filling of the basket. 4.1.3
48、 Curing. After pouring the resin and topping-up, the assembly should be allowed to completely cure before any attempt is made to move it (normally 1 h after gelling). When fully cured the surface will be hard enough to take a scratch from a piece of metal. 4.2 Resin socketing procedures 4.2.1 Mix th
49、e resin system in accordance with the sponsors instructions (see 4.1.2). 4.2.2 Pour the mixture down the inside face of the socket until the basket is full (see 4.1.2). During the pouring and topping-up operation and early stages of gelling, it is essential that all leaks are identified and stopped as such leaks may result in cavities being formed in the neck region. 4.2.3 Puddle with a stiff wire to remove any entrapped air and top-up from the original mix. 4.2.4 Allow the resin mixture to cure without disturbing the rope or socket (see 4.1.3).