Mechanical Analysis And Experimental Research Of Parallel Grooved Drum Multi-layer Winding System

With the rapid development of the marine engineering, port transportation, mining engineering and construction of hydropower stations, the demand of high-lifting hoisting machinery is increasing. It has been found that parallel grooved multi-layer winding system is the best way to solve the problem of high-lifting. In the present design criterion of multi-layer winding drum, multi-layer winding coefficient is chosen according to the number of wire rope layers. However, the actual wire rope arrangement on the drum and the elastic property of wire rope also play decisive roles in determining the multi-layer winding coefficient value. Analyzing the actual stress of the drum accurately is the precondition of ensuring the drums’safety and reliability for meeting the lightweight design requirements. In this dissertation, theory analysis method, finite element numerical simulation method and experimental investigation method are used to explore multi-layer winding coefficient, the pressure acting on the cylinder body and two end plates of parallel grooved drum, wire rope elastic property and the relation between multi-layer winding coefficient and wire rope elastic property according to the actual "pyramid" arrangement of wire rope on parallel grooved drum. The main content and creative aspects are depicted in the following four parts.1. Based on the spacial transform of graphics, the general mathematical geometric models of different wire ropes with defined initial parameters are presented. The geometric model of a kind of complex structure wire rope is set up by using Matlab and Pro/E and Abaqus/Explicit to analyze the stress distribution and the elastic property of the complex structure wire rope under axial tension and lateral compression loads.2. The parallel grooved drum’s stress is analyzed by its being divided into two parts. One part is rotational symmetric shell; the other is rotational symmetric plate. On the basis of the theory of plates and shells, the deformation differential equations of the cylinder body and end plate of parallel grooved drum are deduced and integration constants of the differential equations are obtained under different boundary conditions. 3. Through analyzing the mechanism of inner layer wire rope tension attenuation due to the outer layer wire rope winding, the multi-layer winding coefficient equation is established. Matlab is employed to solve the equation and analyze the residual tension of each layer wire rope. The equation of the relation between the tension of each layer wire rope and the pressure exerting on the end plate is also deduced.4. The experimental rig which can simulate the real operation condition of parallel grooved multi-layer winding system is designed and manufactured. Strain-electricity method is applied to test the stress of the cylinder body and the end plates of the drum on the rig. It is found that the multi-layer winding coefficient obtained by the stress test is in general agreement with that obtained by theoretical calculation. Theoretical analysis and experimental tests suggest that the traditional design method, which set the multi-layer winding coefficient as2.5when the winding layer is more than5, is inaccurate.The results and creative points obtained in this dissertation solved the problems of stress analysis of parallel grooved drums under multi-layer winding and provided a system design theory and calculation methods for designing the accurate thickness with the lightweight design requirements. Finite element analysis method of complex structure wire rope also laid a foundation for studying the mechanism of wire rope damage by numerical simulation analysis method.