our knowledge – your advantage! - pfeifer
TRANSCRIPT
DR.-KARL-LENZ-STRASSE 66 DE-87700 MEMMINGEN TELEFON +49 (0) 83 31-
937-301 TELEFAX +49 (0) 83 31- 937-123 E-MAIL [email protected]
INTERNET www.wirerope.info
Rope and Material Test Center
PFEIFER
2
PFEIFER Rope and Material Test Center PFEIFER analyses all properties of wire ropes and applied materials with extensive tests in the central Rope and Material Test Center at the headquarters in Memmingen and with our facilities at PFEIFER DRAKO in Muelheim/Ruhr. If requested, standard tests can be also done locally in our international subsidiaries.
Knowing that not only the standard catalog values such as weight per meter and minimum breaking force
determine the performance of wire ropes, all prop- erties of the ropes are investigated at PFEIFER in extensive tests. Furthermore, we can ensure the quality of rope end terminations by elaborate
material tests.
Equipped with this knowledge, we will choose the right wire rope for your application and are able to optimize the lifetime in your equipment. This results in consequence to an economic optimi- zation due to cost savings by reduced downtime and rope replacement costs.
Our knowledge – your advantage!
3 Rope and Material Test Center 04/2016
PFEIFER Rope and Material Test Center Index
In our detailed operating manual "Stranded Ropes for General Lifting Applications" we have summarized in- formation about the correct use of your ropes and give hints how to extend the service life based on current standards and our experience.
This is available in many languages both in printed version or as PDF to download at: www.pfeifer.de/Seiltechnik/Download
Multi Layer Spooling Test Tower. . . . . . . . . . . . . . . . . 4
Tension Fatigue Test Facility. . . . . . . . . . . . . . . . . . . . 5
Pull Test Facility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rope Efficiency Test Facility. . . . . . . . . . . . . . . . . . . . 9
Torsion Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notch Impact Test . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dye Penetrate Test. . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Rope and Material Test Center 04/2016
Multi Layer Spooling Test Tower Facility data
Dimensions (L x W x H): 6 m x 4 m x 37,2 m Drive power: 160 kW Rope layers on the drum: up to 5 Reeving of the load: up to 7 falls Test load: variable, up to 53,6 t All determined values are recorded by direct computer interface.
Objectives of tests Performing comparative tests with rotation resistant, high perfor- mance rotation resistant and non-rotation resistant ropes to obtain detailed knowledge about lifetime and spooling behavior of com- mercial ropes and to compare the influence of various rope proper- ties. Furthermore development tests with newly developed wire ropes, fiber ropes, new drum systems, drum half shells and other alternatives will be performed.
Process of the tests In the test a load is lifted and lowered in fully automatic operation by a drum winch. The test rope is spooled onto the drum in several layers. During lowering the drive is in regenerative mode, the elec- trical energy is fed back into the grid. The experiments can be run in a 24 hour operation.
Our knowledge – your advantage Based on the findings we can identify the suitability of ropes for the multi layer spooling, as required especially on mobile and tower cranes and select the best rope for OEMs and operators.
PFEIFER
Tension Fatigue Test Facility
Facility data Tensile force: up to 250 kN Frequency: up to 5 Hz Rope lengths: up to 3 m All determined values are read and recorded by direct computer interface.
Objectives of tests To test ropes and their rope end terminations on their behavior in periodic loading and unloading operations.
Process of the tests Rope test item will be fastened in the attachment and cyclically loaded by a hydraulic cylinder.
Our knowledge – your advantage Based on the obtained results we can optimize the rope end termination perfectly matching to the particularly used rope construction.
PFEIFER
6 Rope and Material Test Center 04/2016
Pull Test Facility Objectives of tests Determination of the breaking force of the rope system.
Process of the tests Wire rope systems (wire rope with rope end termination) are fastened in the device and loaded to breakage or cyclically.
Our knowledge – your advantage Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize the strength of rope end terminations in wire rope systems.
Data pull test machine 6.000 kN (pic. right)
Force: up to 6.000 kN Length: max. 220 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface.
Facility data pull test 800 kN (pic. bottom) Force: up to 800 kN Length: up to 3 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface.
PFEIFER
Pull Test Facility
Further pull test facilities with capacities up to 2,000 kN: PFEIFER AUSTRIA, Asten PFEIFER CHINA, Shanghai PFEIFER RUSSIA, St. Petersburg PFEIFER ISOFER, Switzerland, Knonau PFEIFER DRAKO Ltd., UK, Crewe PFEIFER USA, Hampton VA MIDDLE EAST, Dubai
PFEIFER
8 Rope and Material Test Center 04/2016
Test Facility for the determination of Bending Fatigue Strength Facility data
Rope diameter: up to 25 mm Force: up to 200 kN Rope pulley diameter 240 up to 625 mm Standard rope diameter: 16 mm, 22 mm D/d ratio: 16, 20, 22, 25 Angle of inclination variable: 0° bis 4°
Objectives of tests Determination of the bending fatigue strength of wire ropes by variation of different parameters.
Process of the tests Test ropes and sheaves will be installed; by means of an eccentric drive the ropes are bent back and forth over the test sheave.
Our knowledge – your advantage Based on the results of the obtained results we can select the optimum rope construction for applica- tions with high bending cycles or give recommenda- tions for economically D/d ratio.
PFEIFER
Rope Efficiency Test Facility Facility data
Rope diameter: up to 25 mm Rope minimum breaking forces: up to 700 kN
Objectives of tests Determination of the efficiency of wire ropes.
Process of the tests The test piece is placed over a rope sheave and both rope ends are loaded equally with weights. For the determination of the efficiency extra weight will be added on one side gradually until the internal friction of the rope is exceeded and the rope starts to run over the sheave. The ratio between the additionally applied weight loads to base load calculates into the degree of wire rope efficiency.
Our knowledge – your advantage Knowing the efficiency grade is mainly important in reeving many falls (e.g. reeving of mobile crane hook blocks). Ropes with high efficiency require significantly lower winch drive power when lifting loads and allow to lower only the unloaded hook block, which has great importance for the design and construction of your systems.
Torsion Test Facility Facility data
Force up: up to 200 kN Rope lengths: up to 13 m
Objectives of tests Determine torque behavior of ropes under load.
Process of the tests Ropes will be fastened rotating freely at one end and loaded with defined forces. The resulting rotation is checked by suitable meas- uring equipment. Also the torque is measured.
Our knowledge – your advantage Based on the gained results we determine the rotation resistance of rotation resistant and high performance rotation resistant ropes and can choose the best rope for your application.
PFEIFER
Test Facility for Lateral Pressure Resistance Facility data
Rope diameter: up to 25 mm
Objectives of tests Determination of deformation of wire ropes under lateral pressure.
Process of the tests The test rope is inserted between special steel prisms and loaded with defined lateral forces. The changing of the diameter (ovaliza- tion) is determined with mathematical precision in the x-and y- direction.
Our knowledge – your advantage Knowledge of the degree of ovalization is essantial in the selection of wire ropes for use in multi layer spooling.
Notch Impact Test Facility data
Notch impact energy: 300/150 J
Objectives of tests Determining the material toughness depending on the temperature.
Process of the tests The specimen (sample of material) is fixed on each end and the impact pendulum hammer hits the middle of the specimen at the level of the previously machined notch. The sample breaks at the notch and absorbs a specific energy. On the basis of the remaining energy in the hammer, the material toughness at a specific temper- ature can be determined.
Our knowledge – your advantage Ensuring the material toughness is crucial in the selection and processing of material for rope end terminations.
PFEIFER
Spectral Analysis
Hardness testing acc. Rockwell, Brinel, Vickers
Force range: 1 bis 250 kg All determined values are read and recorded by the direct computer connection.
Objectives of tests Traditional hardness testing of metals and plastics.
Process of the tests The hardness test equipment tests acc. Rockwell and determines the ball indentation hardness. In addition all common optical hard- ness testing methods (Vickers, Brinell) and depth measurements (Rockwell) conforming to standards are covered in the load range.
Our knowledge – your advantage In order to correctly select and process the material for rope end terminations, we must know and permanently secure the material hardness.
Facility data Max. material thickness: up to 5.000 mm
Objectives of tests Non-destructive testing of components for material defects such as bubbles, cracks or transverse defects.
Process of the tests The principle of ultrasonic testing is based on the fact that sound waves propagate at different speeds in different media. Changes in acoustic properties at interfaces (for example, voids, inclusion, tear) in the interior of the part to be tested reflect the ultrasound pulse and send it to the vibrator in the probe, which acts both as transmitter and receiver. Based on the measured time difference, a signal image is produced and displayed on a monitor. Through this image, the position and the size of the error can be determined.
Our knowledge – your advantage The guarantee of error-free components is crucial for us in the selection and processing of materials for wire rope end terminations.
Ultrasonic
Facility data Optical Emission Spectro- meter for metal analysis
Objectives of tests Non-destructive determination of the chemical material composition.
Process of the tests In the optical emission spectrometry atoms of the probe are stimu- lated with energy from a spark that is created between the sample and the electrode. Through the energy of the spark the electrons in the sample emit light, which is transmitted into a spectral grid. By measuring the intensity of the spectral lines, the material composi- tion can be precisely determined.
Our knowledge – your advantage Material for rope end terminations will only be selected or processed if we know and can permanently secure the chemical composition of the materials.
PFEIFER
Dye Penetration Test Facility data
Dye Penetration Test acc. DIN EN 571-1 Objectives of tests The dye penetration test is a non-destructive material test, in which the capillary forces of almost invisible superficial cracks and pores are used to make them visible.
Process of the tests At dye penetration testing the penetrant dye (Contraster) is applied to the surface of the sample. The creep properties of the penetrant is high, uses the capillary action of the finest material separations and has a strong color contrast to the developer. After the exposure time depending on the material the surface is cleaned, dried and the developer is applied. The developer is a fine-grained powder suspension with a suitable solvent. Due to the capillary action of its internal cavities, it draws out remaining penetrant dye from the su- perficial cracks. The high color contrast makes it easy to locate the flaw positions and to determine the crack paths.
Our knowledge – your advantage Through the examination of the rope end termina- tions we can guarantee impeccable quality and safe usability.
Elongation and Pull Test Facility Facility data
Force: up to 50 kN Length: max. 1.000 mm Tension fatigue tests possible All determined values are read and recorded by direct com- puter interface.
Objectives of tests Determination of elongation behavior as well as rope system and material breaking forces.
Process of the tests Rope systems (rope with rope end termination) and material sam- ples are fastened in the attachments and loaded for elongation or eventually until destruction rsp. loaded cyclically.
Our knowledge – your advantage Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize rope end terminations in rope systems. Also know- ing and ensuring the material properties is essential for us in the selection and processing of materials for rope end terminations.
PFEIFER
Facility data Magnaflux Test acc. DIN EN 1330-7
Objectives of tests The magnaflux test is a method for the detection of cracks in or near the surface.
Process of the tests Suspended iron powder is applied to the test object. By magnetiza- tion and suitable lighting even the finest hairline cracks can be rec- ognized.
Our knowledge – your advantage The guarantee of perfect quality of the materials is the basis for error-free rope end terminations and thus secure rope systems.
Magnaflux Test
14 Rope and Material Test Center 04/2016
Our knowledge – your advantage The knowledge and ensuring the metallic layer thick- nesses (e.g. galvanizing of steel cables) for us are critical in the selection and processing of steel cables.
Facility data Coulometric layer thickness measuring acc. DIN EN ISO 2177
Objectives of tests Determination of the metallic layer thickness on components – such as zinc layer thickness on wires of rope.
Process of the tests In the coulometric coating thickness measurement, a metal layer is replaced by an electrolyte from its metallic or nonmetallic base material by a controlled electrical current flow, thus reversal of the electroplating process. The required amount of electrical curent for the layer separation is directly proportional to the replaced metal mass. The result is a clear correlation between release time and layer thickness since release and the current release surface are kept constant.
Coating Thickness Measuring
Facility data Magnetic inductive measurement acc. DIN EN ISO 2178
Objectives of tests Determination of the galvanic layer thicknesses on metallic con- struction parts – e.g. zinc layer thickness on wires of steel cables.
Process of the tests At the magnetic induction method a magnetic flux is generated by a current in the primary coil of an electromagnet, which in turn de- velops an inductive voltage. The layer thickness is determined by measuring the change of the magnetic flux, and thus the induced voltage.
Facility data Microscope with camera, 60-times magnification
150 watt halogen cold light gooseneck light conductor
All determined values are read and recorded by direct com- puter interface.
Objectives of tests Determination of microscopic changes on specimens.
Process of the tests The specimen is clamped, illuminated by halogen cold light and the area to be examined displayed visually enlarged at the monitor.
Our knowledge – your advantage The knowledge and ensuring the material properties are crucial in the selection and processing of our materials. Similar microscopic inspections in rope investigations are necessary.
Microscopic Analysis
PFEIFER-measurement devices: by pros – for pros!
Measurement equipment case 75 Content:
Rope caliper 75 made of galvanized steel with attached wide jaws
Recommended for the frequent measuring of ropes in the most common diameters
Rope diameter 5 – 28 mm, 12 – 45 mm, 21 – 60 mm, 5 – 60 mm Further combinations of the 5 differ- ent groove gauges kits on request
Product advantages Combine your own measurement equipment case according to your needs!
Measurement devices Based on our long-term practical experience of rope drive inspection, we created the following measurement devices kit.
These measurement devices are used by our rope experts for each inspection and thereby approved for general use.
Rope caliper 40 With attached wide jaws
Product advantages • Recommended for frequent
measurement of ropes with the most common diameters up to 40 mm
• Enables quick and easy check – wide jaws reduce measuring faults
Rope caliper 150 With attached extra wide jaws and adapter plates for big rope diameters
Product advantages • Recommended for frequent meas-
urement of ropes with diameters up to 150 mm
• Enables quick and easy check – wide jaws reduce measuring faults
Propeller Stainless steel
Rope diameter 15 mm, 20 mm, 24 mm Further sizes on request
Product advantages Recommended for the frequent check of rope drives with a specific diameter
Measurement equipment case 150 Content:
Rope caliper 150 Groove gauges „Bolt“ with 5 kits (see picture measurement equip- ment case 75)
Rope diameter 5 – 60 mm
Product advantages The complete measurement equipment case for the frequent professional groove inspection!
Ring Stainless steel
Rope diameter 5 – 20 mm, 20 – 40 mm, 40 – 60 mm, 60 – 75 mm
Product advantages Recommended for the frequent check of rope drives with the most common rope diameters
Rope service – starter kit Content:
2x PFEIFER RL-S Wire rope lubrication Spray can
1x Groove-gauge-Kit Worker 1x Pair gloves 1x Rope caliper 40 1x Yard stick 1x Steel wire brush
Product advantages Allows quick and easy control as well as professional care of your wire ropes
PFEIFER – at your service all over the world
GERMANY Memmingen TEL +49-8331-937-301 E-MAIL [email protected] WEB www.pfeifer.info
Hamburg TEL +49-40-780-463-0 E-MAIL [email protected] WEB www.pfeifer.info
AUSTRIA Asten TEL +43-7224-66224-0 E-MAIL [email protected] WEB www.pfeifer-austria.at
CHINA Shanghai TEL +86-21-56778006 E-MAIL [email protected] WEB www.pfeifer.com.cn
HUNGARY Budapest TEL +36-1-2601014 E-MAIL [email protected] WEB www.pfeifer-garant.hu
LUXEMBOURG Schifflange TEL +352-574242 E-MAIL [email protected] WEB www.pfeifer-sogequip.lu
POLAND Wrocaw TEL +48-71-3980760 E-MAIL [email protected] WEB www.pfeifer.pl
RUSSIA Moscow TEL +7-495-363-01-27 E-MAIL [email protected] WEB www.pfeiferrussia.ru
St. Petersburg TEL +7-812-740-12-24 E-MAIL [email protected] WEB www.pfeiferrussia.ru
SPAIN Madrid TEL +34-91-659-3185 E-MAIL [email protected] WEB www.pfeifer.es
SWITZERLAND Knonau TEL +41-44-768-55-55 E-MAIL [email protected] WEB www.pfeifer-isofer.ch
UNITED KINGDOM Crewe TEL +44-1270-587728 E-MAIL [email protected] WEB www.pfeifer.co.uk
Southampton TEL +44-23-8066-5470 E-MAIL [email protected] WEB www.ropeandtackle.com
USA Hampton TEL +1-757-825-2544 E-MAIL [email protected] WEB www.pfeifer.us.com
Houston TEL +1-832-827-2923
St. Petersburg Moscow
Rope and Material Test Center
PFEIFER
2
PFEIFER Rope and Material Test Center PFEIFER analyses all properties of wire ropes and applied materials with extensive tests in the central Rope and Material Test Center at the headquarters in Memmingen and with our facilities at PFEIFER DRAKO in Muelheim/Ruhr. If requested, standard tests can be also done locally in our international subsidiaries.
Knowing that not only the standard catalog values such as weight per meter and minimum breaking force
determine the performance of wire ropes, all prop- erties of the ropes are investigated at PFEIFER in extensive tests. Furthermore, we can ensure the quality of rope end terminations by elaborate
material tests.
Equipped with this knowledge, we will choose the right wire rope for your application and are able to optimize the lifetime in your equipment. This results in consequence to an economic optimi- zation due to cost savings by reduced downtime and rope replacement costs.
Our knowledge – your advantage!
3 Rope and Material Test Center 04/2016
PFEIFER Rope and Material Test Center Index
In our detailed operating manual "Stranded Ropes for General Lifting Applications" we have summarized in- formation about the correct use of your ropes and give hints how to extend the service life based on current standards and our experience.
This is available in many languages both in printed version or as PDF to download at: www.pfeifer.de/Seiltechnik/Download
Multi Layer Spooling Test Tower. . . . . . . . . . . . . . . . . 4
Tension Fatigue Test Facility. . . . . . . . . . . . . . . . . . . . 5
Pull Test Facility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rope Efficiency Test Facility. . . . . . . . . . . . . . . . . . . . 9
Torsion Test Facility . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Notch Impact Test . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dye Penetrate Test. . . . . . . . . . . . . . . . . . . . . . . . . . 12
4 Rope and Material Test Center 04/2016
Multi Layer Spooling Test Tower Facility data
Dimensions (L x W x H): 6 m x 4 m x 37,2 m Drive power: 160 kW Rope layers on the drum: up to 5 Reeving of the load: up to 7 falls Test load: variable, up to 53,6 t All determined values are recorded by direct computer interface.
Objectives of tests Performing comparative tests with rotation resistant, high perfor- mance rotation resistant and non-rotation resistant ropes to obtain detailed knowledge about lifetime and spooling behavior of com- mercial ropes and to compare the influence of various rope proper- ties. Furthermore development tests with newly developed wire ropes, fiber ropes, new drum systems, drum half shells and other alternatives will be performed.
Process of the tests In the test a load is lifted and lowered in fully automatic operation by a drum winch. The test rope is spooled onto the drum in several layers. During lowering the drive is in regenerative mode, the elec- trical energy is fed back into the grid. The experiments can be run in a 24 hour operation.
Our knowledge – your advantage Based on the findings we can identify the suitability of ropes for the multi layer spooling, as required especially on mobile and tower cranes and select the best rope for OEMs and operators.
PFEIFER
Tension Fatigue Test Facility
Facility data Tensile force: up to 250 kN Frequency: up to 5 Hz Rope lengths: up to 3 m All determined values are read and recorded by direct computer interface.
Objectives of tests To test ropes and their rope end terminations on their behavior in periodic loading and unloading operations.
Process of the tests Rope test item will be fastened in the attachment and cyclically loaded by a hydraulic cylinder.
Our knowledge – your advantage Based on the obtained results we can optimize the rope end termination perfectly matching to the particularly used rope construction.
PFEIFER
6 Rope and Material Test Center 04/2016
Pull Test Facility Objectives of tests Determination of the breaking force of the rope system.
Process of the tests Wire rope systems (wire rope with rope end termination) are fastened in the device and loaded to breakage or cyclically.
Our knowledge – your advantage Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize the strength of rope end terminations in wire rope systems.
Data pull test machine 6.000 kN (pic. right)
Force: up to 6.000 kN Length: max. 220 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface.
Facility data pull test 800 kN (pic. bottom) Force: up to 800 kN Length: up to 3 m Tension fatigue tests possible All determined values are read and recorded by direct computer interface.
PFEIFER
Pull Test Facility
Further pull test facilities with capacities up to 2,000 kN: PFEIFER AUSTRIA, Asten PFEIFER CHINA, Shanghai PFEIFER RUSSIA, St. Petersburg PFEIFER ISOFER, Switzerland, Knonau PFEIFER DRAKO Ltd., UK, Crewe PFEIFER USA, Hampton VA MIDDLE EAST, Dubai
PFEIFER
8 Rope and Material Test Center 04/2016
Test Facility for the determination of Bending Fatigue Strength Facility data
Rope diameter: up to 25 mm Force: up to 200 kN Rope pulley diameter 240 up to 625 mm Standard rope diameter: 16 mm, 22 mm D/d ratio: 16, 20, 22, 25 Angle of inclination variable: 0° bis 4°
Objectives of tests Determination of the bending fatigue strength of wire ropes by variation of different parameters.
Process of the tests Test ropes and sheaves will be installed; by means of an eccentric drive the ropes are bent back and forth over the test sheave.
Our knowledge – your advantage Based on the results of the obtained results we can select the optimum rope construction for applica- tions with high bending cycles or give recommenda- tions for economically D/d ratio.
PFEIFER
Rope Efficiency Test Facility Facility data
Rope diameter: up to 25 mm Rope minimum breaking forces: up to 700 kN
Objectives of tests Determination of the efficiency of wire ropes.
Process of the tests The test piece is placed over a rope sheave and both rope ends are loaded equally with weights. For the determination of the efficiency extra weight will be added on one side gradually until the internal friction of the rope is exceeded and the rope starts to run over the sheave. The ratio between the additionally applied weight loads to base load calculates into the degree of wire rope efficiency.
Our knowledge – your advantage Knowing the efficiency grade is mainly important in reeving many falls (e.g. reeving of mobile crane hook blocks). Ropes with high efficiency require significantly lower winch drive power when lifting loads and allow to lower only the unloaded hook block, which has great importance for the design and construction of your systems.
Torsion Test Facility Facility data
Force up: up to 200 kN Rope lengths: up to 13 m
Objectives of tests Determine torque behavior of ropes under load.
Process of the tests Ropes will be fastened rotating freely at one end and loaded with defined forces. The resulting rotation is checked by suitable meas- uring equipment. Also the torque is measured.
Our knowledge – your advantage Based on the gained results we determine the rotation resistance of rotation resistant and high performance rotation resistant ropes and can choose the best rope for your application.
PFEIFER
Test Facility for Lateral Pressure Resistance Facility data
Rope diameter: up to 25 mm
Objectives of tests Determination of deformation of wire ropes under lateral pressure.
Process of the tests The test rope is inserted between special steel prisms and loaded with defined lateral forces. The changing of the diameter (ovaliza- tion) is determined with mathematical precision in the x-and y- direction.
Our knowledge – your advantage Knowledge of the degree of ovalization is essantial in the selection of wire ropes for use in multi layer spooling.
Notch Impact Test Facility data
Notch impact energy: 300/150 J
Objectives of tests Determining the material toughness depending on the temperature.
Process of the tests The specimen (sample of material) is fixed on each end and the impact pendulum hammer hits the middle of the specimen at the level of the previously machined notch. The sample breaks at the notch and absorbs a specific energy. On the basis of the remaining energy in the hammer, the material toughness at a specific temper- ature can be determined.
Our knowledge – your advantage Ensuring the material toughness is crucial in the selection and processing of material for rope end terminations.
PFEIFER
Spectral Analysis
Hardness testing acc. Rockwell, Brinel, Vickers
Force range: 1 bis 250 kg All determined values are read and recorded by the direct computer connection.
Objectives of tests Traditional hardness testing of metals and plastics.
Process of the tests The hardness test equipment tests acc. Rockwell and determines the ball indentation hardness. In addition all common optical hard- ness testing methods (Vickers, Brinell) and depth measurements (Rockwell) conforming to standards are covered in the load range.
Our knowledge – your advantage In order to correctly select and process the material for rope end terminations, we must know and permanently secure the material hardness.
Facility data Max. material thickness: up to 5.000 mm
Objectives of tests Non-destructive testing of components for material defects such as bubbles, cracks or transverse defects.
Process of the tests The principle of ultrasonic testing is based on the fact that sound waves propagate at different speeds in different media. Changes in acoustic properties at interfaces (for example, voids, inclusion, tear) in the interior of the part to be tested reflect the ultrasound pulse and send it to the vibrator in the probe, which acts both as transmitter and receiver. Based on the measured time difference, a signal image is produced and displayed on a monitor. Through this image, the position and the size of the error can be determined.
Our knowledge – your advantage The guarantee of error-free components is crucial for us in the selection and processing of materials for wire rope end terminations.
Ultrasonic
Facility data Optical Emission Spectro- meter for metal analysis
Objectives of tests Non-destructive determination of the chemical material composition.
Process of the tests In the optical emission spectrometry atoms of the probe are stimu- lated with energy from a spark that is created between the sample and the electrode. Through the energy of the spark the electrons in the sample emit light, which is transmitted into a spectral grid. By measuring the intensity of the spectral lines, the material composi- tion can be precisely determined.
Our knowledge – your advantage Material for rope end terminations will only be selected or processed if we know and can permanently secure the chemical composition of the materials.
PFEIFER
Dye Penetration Test Facility data
Dye Penetration Test acc. DIN EN 571-1 Objectives of tests The dye penetration test is a non-destructive material test, in which the capillary forces of almost invisible superficial cracks and pores are used to make them visible.
Process of the tests At dye penetration testing the penetrant dye (Contraster) is applied to the surface of the sample. The creep properties of the penetrant is high, uses the capillary action of the finest material separations and has a strong color contrast to the developer. After the exposure time depending on the material the surface is cleaned, dried and the developer is applied. The developer is a fine-grained powder suspension with a suitable solvent. Due to the capillary action of its internal cavities, it draws out remaining penetrant dye from the su- perficial cracks. The high color contrast makes it easy to locate the flaw positions and to determine the crack paths.
Our knowledge – your advantage Through the examination of the rope end termina- tions we can guarantee impeccable quality and safe usability.
Elongation and Pull Test Facility Facility data
Force: up to 50 kN Length: max. 1.000 mm Tension fatigue tests possible All determined values are read and recorded by direct com- puter interface.
Objectives of tests Determination of elongation behavior as well as rope system and material breaking forces.
Process of the tests Rope systems (rope with rope end termination) and material sam- ples are fastened in the attachments and loaded for elongation or eventually until destruction rsp. loaded cyclically.
Our knowledge – your advantage Based on the obtained results, we can verify the safety-relevant minimum breaking force or optimize rope end terminations in rope systems. Also know- ing and ensuring the material properties is essential for us in the selection and processing of materials for rope end terminations.
PFEIFER
Facility data Magnaflux Test acc. DIN EN 1330-7
Objectives of tests The magnaflux test is a method for the detection of cracks in or near the surface.
Process of the tests Suspended iron powder is applied to the test object. By magnetiza- tion and suitable lighting even the finest hairline cracks can be rec- ognized.
Our knowledge – your advantage The guarantee of perfect quality of the materials is the basis for error-free rope end terminations and thus secure rope systems.
Magnaflux Test
14 Rope and Material Test Center 04/2016
Our knowledge – your advantage The knowledge and ensuring the metallic layer thick- nesses (e.g. galvanizing of steel cables) for us are critical in the selection and processing of steel cables.
Facility data Coulometric layer thickness measuring acc. DIN EN ISO 2177
Objectives of tests Determination of the metallic layer thickness on components – such as zinc layer thickness on wires of rope.
Process of the tests In the coulometric coating thickness measurement, a metal layer is replaced by an electrolyte from its metallic or nonmetallic base material by a controlled electrical current flow, thus reversal of the electroplating process. The required amount of electrical curent for the layer separation is directly proportional to the replaced metal mass. The result is a clear correlation between release time and layer thickness since release and the current release surface are kept constant.
Coating Thickness Measuring
Facility data Magnetic inductive measurement acc. DIN EN ISO 2178
Objectives of tests Determination of the galvanic layer thicknesses on metallic con- struction parts – e.g. zinc layer thickness on wires of steel cables.
Process of the tests At the magnetic induction method a magnetic flux is generated by a current in the primary coil of an electromagnet, which in turn de- velops an inductive voltage. The layer thickness is determined by measuring the change of the magnetic flux, and thus the induced voltage.
Facility data Microscope with camera, 60-times magnification
150 watt halogen cold light gooseneck light conductor
All determined values are read and recorded by direct com- puter interface.
Objectives of tests Determination of microscopic changes on specimens.
Process of the tests The specimen is clamped, illuminated by halogen cold light and the area to be examined displayed visually enlarged at the monitor.
Our knowledge – your advantage The knowledge and ensuring the material properties are crucial in the selection and processing of our materials. Similar microscopic inspections in rope investigations are necessary.
Microscopic Analysis
PFEIFER-measurement devices: by pros – for pros!
Measurement equipment case 75 Content:
Rope caliper 75 made of galvanized steel with attached wide jaws
Recommended for the frequent measuring of ropes in the most common diameters
Rope diameter 5 – 28 mm, 12 – 45 mm, 21 – 60 mm, 5 – 60 mm Further combinations of the 5 differ- ent groove gauges kits on request
Product advantages Combine your own measurement equipment case according to your needs!
Measurement devices Based on our long-term practical experience of rope drive inspection, we created the following measurement devices kit.
These measurement devices are used by our rope experts for each inspection and thereby approved for general use.
Rope caliper 40 With attached wide jaws
Product advantages • Recommended for frequent
measurement of ropes with the most common diameters up to 40 mm
• Enables quick and easy check – wide jaws reduce measuring faults
Rope caliper 150 With attached extra wide jaws and adapter plates for big rope diameters
Product advantages • Recommended for frequent meas-
urement of ropes with diameters up to 150 mm
• Enables quick and easy check – wide jaws reduce measuring faults
Propeller Stainless steel
Rope diameter 15 mm, 20 mm, 24 mm Further sizes on request
Product advantages Recommended for the frequent check of rope drives with a specific diameter
Measurement equipment case 150 Content:
Rope caliper 150 Groove gauges „Bolt“ with 5 kits (see picture measurement equip- ment case 75)
Rope diameter 5 – 60 mm
Product advantages The complete measurement equipment case for the frequent professional groove inspection!
Ring Stainless steel
Rope diameter 5 – 20 mm, 20 – 40 mm, 40 – 60 mm, 60 – 75 mm
Product advantages Recommended for the frequent check of rope drives with the most common rope diameters
Rope service – starter kit Content:
2x PFEIFER RL-S Wire rope lubrication Spray can
1x Groove-gauge-Kit Worker 1x Pair gloves 1x Rope caliper 40 1x Yard stick 1x Steel wire brush
Product advantages Allows quick and easy control as well as professional care of your wire ropes
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