Lost-wax Casting Fixed Φ16 Wire Rope End Fitting Assembly Introduction
The cast fixed Φ16 rope head assembly is a critical load-bearing component in elevator suspension systems, primarily used for the fixed connection of elevator steel wire ropes to the elevator car and counterweight device. This product is manufactured using a high-strength casting process, designed for 16mm diameter elevator-specific steel wire ropes.
Product Overview
The cast fixed Φ16 rope head assembly is a critical load-bearing component in elevator suspension systems, primarily used for the fixed connection of elevator steel wire ropes to the elevator car and counterweight device. This product is manufactured using a high-strength casting process, designed for 16mm diameter elevator-specific steel wire ropes. It features a compact structure, strong load-bearing capacity, and convenient installation, and is widely used in the suspension systems of various passenger elevators, freight elevators, and service elevators.
Structural Components
Rope Head Cone
Precisely cast from high-quality ZG270-500 cast steel material. The internal taper design conforms to the GB/T 16895.25 standard. The cone hole depth matches the steel wire rope diameter, ensuring a reliable mechanical self-locking structure after cold shrinkage of the steel wire rope. The cone surface is shot blasted to remove rust, achieving a roughness of Ra12.5μm, enhancing friction with the rope clamp.
Made of Q355B low-alloy high-strength structural steel, with a thickness of ≥16mm. It features Φ22mm mounting holes (for M20 connecting bolts), with hole spacing designed according to elevator traction machine layout standards. The plate edges are rounded to eliminate stress concentration points.
M30×1.5 fine-pitch thread design, made of 45# steel with heat treatment (hardness HB220-250), combined with a lock washer for double anti-loosening. The thread accuracy reaches 6g grade, ensuring uniform preload distribution.
Equipped with a Φ28mm cylindrical helical compression spring, made of 60Si2MnA spring steel, with a free length of 85mm, a working stroke of 25mm, and a deformation of ≤5mm under rated load, providing excellent cushioning and vibration damping performance. III. Technical Parameters
● Rated Load: ≥20kN (single unit)
● Applicable Wire Rope: Φ16mm (8×19S+FC-1670MPa)
● Breaking Load: ≥120kN (safety factor 6 times)
● Operating Temperature: -20℃~+80℃
● Surface Treatment: Rope end cone galvanized (zinc layer thickness ≥85μm), rope end plate hot-dip galvanized
● Overall Weight: 3.2±0.1kg
Working Principle
After the wire rope passes through the conical hole of the rope end cone, a special crimping tool is used to upset the rope end to form a rope head. A locking nut between the cone and the rope end plate applies a pre-tightening force, causing radial compression deformation of the wire rope within the conical hole, creating a double fixing effect of friction and mechanical self-locking. The spring assembly absorbs impact loads during elevator operation, reducing the dynamic stress on the wire rope and improving system stability.
Installation Requirements
1. Before installation, check the wire rope diameter deviation (±0.15mm) and surface damage.
2. Apply special lubricating grease (polyurea grease) to the conical hole of the rope end cone.
3. Locking nut pre-tightening torque: 280~320N·m (measured using a torque wrench)
4. Spring compression should be controlled within the range of 15~20mm.
5. After installation, a static load test of 1.25 times the rated load must be performed, holding the load for 10 minutes without permanent deformation.
Applicable Standards
• GB/T 10058-2009 "Technical Conditions for Elevators"
• GB/T 16895.25-2012 "Electrical Installations of Buildings Part 25: Electrical Installations of Elevators, Escalators and Moving Walks"
• JB/T 8545-2010 "Elevator Rope Head Assembly"
Safety Features
1. Fully cast structure with no welding points, avoiding strength loss due to welding defects.
2. Equipped with anti-loosening marking lines for easy daily inspection of nut looseness.
3. Limit rings are installed at the spring ends to prevent spring failure due to excessive compression.
4. Stress relief holes are provided on the rope head plate to reduce stress concentration in the bolt connection area.
Application Scenarios
● Elevator car suspension systems with machine room
● Counterweight device connection for machine roomless elevators
● Special elevators such as medical elevators and panoramic elevators
● Renovation and upgrading of old elevator suspension systems
Maintenance
Monthly inspection
Spring working condition, nut tightening, and wire rope wear.
Every six months
Measure the change in spring free length (allowable deviation ±2mm).
Annually
Conduct load testing and check overall deformation.
Five-year replacement cycle
Even if there is no obvious damage to the appearance, the spring assembly must be replaced.
Quality Control
Raw material incoming inspection
Chemical composition spectral analysis, mechanical properties tensile test.
01
Casting process
Using lost-wax casting process, dimensional tolerance CT8 grade, internal quality UT flaw detection (Level II qualified).
02
Finished product inspection
100% magnetic particle testing (MT) for surface defects, and sampling for destructive load testing.
03
Factory documents
Provide material certificate, flaw detection report, and load test certificate.
04
Note: This product needs to undergo type testing with the complete elevator system. Installation should follow the installation manual provided by the elevator manufacturer. Overloading or unauthorized modification of structural components is strictly prohibited.
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