1. why must wire ropes be inspected and examined?

为什么钢丝绳必须要检验检测

Wire ropes are consumable items with a limited life during service the physical properties of a wire rope will change.

钢丝绳是有一定寿命的消耗品，在服务过程中钢丝绳的物理性质将会发生变化。

At the commencement of service, the individual wires and strands settle into position and the rope breaking strength increases. After reaching a maximum it decreases rapidly.

在服务的开始，个体的钢丝及绳股安装到位，绳子的破断拉力增大，在达到最大极限后破断拉力迅速减小。

This decrease in breaking strength is caused by the progressive loss of the metallic cross-section due to abrasion and corrosion, by wire breaks and by changes in the structure of the rope.

这种破断拉力的减小是由于磨损和侵蚀引起金属截面积的累积损失，断丝和绳子的结构变化所导致的。

A chain represents a series connection of load bearing elements. If only one link in the chain breaks, the whole lifting device will fail completely. A wire rope represents a parallel connection of load bearing elements and consequently it can still be operated safely after one or more wire breaks.

链条体现了一种连续连接的承载原理。只要链条中有一级链环断开，整个提升装置也将彻底失效。钢丝绳体现了一种平行连接的承载原理，因此在断了一根或者更多的钢丝，它仍然能够安全地操作。

Generally, there is a steady rate of increases in the number of wire breaks during the life of the rope.

一般地说，在绳子的寿命过程中，断丝数目的增大是有一个稳定的比率的。

One of the objectives of inspecting and examining a wire rope is to supervise the normal process of deterioration so that the rope can be removed from service before become a hazard to safety. 检验检测钢丝绳的目的之一就是监测绳子退化的正常过程，在绳子变成对安全造成危害之前能够将它从服务中撤除掉。

Another benefit of the inspection and examination procedures is to detect unexpected damage or corrosion.

检验检测程序的另一个好处是发觉意想不到的损害或侵蚀。

Inspections and examinations, properly carried out, ensure the discard of a rope before failure. In addition, precautions can be taken to avoid a recurrence of damage or excessive wear to future ropes.

正确实施检验检测确保绳子在失效之前报废。而且，能够采取防范措施避免新绳子受到重复的损害和过度的磨损。

2.what is inspection, what is examination？

An inspection is a careful and critical assessment of the rope and fittings carried out without dismantling.

检验是对钢丝绳和相应的配件仔细而公正的评估，实施起来无须将钢丝绳从设备上拆卸下。 An examination is a careful and critical assessment of the rope and fittings carried out by a competent person. This should include, where necessary, a visual assessment of the internal

condition of the rope, supplemented by other means such as measurement and non destructive testing. In order for end fittings to be examined properly they may need to be dismantled.

检测是对钢丝绳和相应的配件仔细而公正的评估，实施起来须要能够胜任的人员来实施。内容应包括：必要的地方；钢丝绳内部状况形象的评估，诸如测量和非破坏性的试验等其他一些方法的补充。为了绳头配件的完全检测，绳子和配件可能需要拆卸下来。

3 .when must wire ropes be inspected?

什么时候必须检验钢丝绳？

Wire ropes should be inspected at the start of each shift, work period or more frequently, depending upon past experience.

每一次变换倍率的开始钢丝绳应该得到检验，工作期间或者更频繁的检验依赖于以往的经验。

Usually this inspection will be carried out by the operator of the individual piece of equipment or possibly by a member of the work force specially appointed.

通常这种检验由特定设备的操作人来实施或者由指定的一些工厂人员来实施。

The inspection should be a visual assessment of the condition of as much of the rope length as possible, including the points of attachment to the equipment.

检验应该是绳子条件的形象评估，这种评估是对尽可能的绳长，包括连接设备的配件点。 When a rope has been removed from equipment and later fitted to the same or different equipment, it should to be inspected after fitting but before resuming service.

一根绳子从设备上拆卸下来，稍后又装到相同或不同的设备上，在安装完毕重新投入使用前应该得到检验。

If at any time a change in the rope condition is suspected, it should be reported immediately and equipment taken out of service until the rope has been examined by a competent person. As a result of this examination it may be prudent to review and amend the scope and frequency of the inspections.

任何时候如果绳子状况有令人怀疑的变化，应该立刻报告，设备退出服务，直到绳子得到有胜任能力的人员的检测。根据检测的结果，可以谨慎地回顾并修改检验的范围和频率。

4. when must wire ropes be examined?

什么时候必须检测钢丝绳？

The Factories Act 1961 Section 26, The Construction (Lifting Operations) Regulations No.1581 and the Offshore Installations (Operational Safety, Health and Welfare) Regulations 1976 No.1019 all require a thorough rope examination at least once in every period of six months.

The Factories Act 1961第26部分;The Construction (Lifting Operations) Regulations第1581条;the Offshore Installations (Operational Safety, Health and Welfare) Regulations 1976第1019条都要求在每6个月的周期内最少对钢丝绳进行一次彻底地检测。

The Shipbuilding and Ship-repairing Regulations 1960 requires a thorough examination every three months or monthly after first broken wire has been discovered.

The Shipbuilding and Ship-repairing Regulations 1960 要求每三个月彻底检验一次；第一根断丝被发觉后，每月彻底检验一次。

One of the statutory regulations listed above will apply to the location and type of rope using

equipment being examined.

根据使用在设备上的钢丝绳类型及使用的场所，使用上列法定规范中对应的方法进行检测。 It is the responsibility of the individual to institute and maintain a program of periodic examination which satisfies the requirements of the appropriate regulations and the specific operating conditions of the equipment.

为满足相应规范和设备的特殊操作条件要求，建立和维护一个定期检测计划是特定人员的职责。

Examination should be carried out at regular intervals. The intervals should be scheduled so that any damage will be detected early.

检测应定期进行，间隔时间应该计划好，这样损伤会被及早发现。

According to B.S.6570 examinations should be carried out at regular intervals, the frequency of which will be influenced by the following:

根据BS6570标准，检测应该每隔一段时间进行，检测频率受下列因素影响

a) statutory requirements法定的要求

b) type of appliance and/or design of the system应用类型或系统设计

c) operational environmental conditions操作的环境条件

d) method and frequency of operation操作的方法和频率

e) manufacturer’s recommendations生产商的推荐

f) results of previous inspections and examinations之前的检验检测结果

g) experience with previous ropes on the appliance or system之前绳子在系统中或用具上使用

经验

During the first few weeks after the installation of a new rope the daily inspection can be used to monitor performance as the rope might not be suited to the equipment.

在新绳子安装后的最初几周内，日常的检验可以用于监测绳子的性能，因为绳子很可能不适应设备

The intervals between the examinations should also be reduced after the first broken wire or other damage has been detected.

当第一根断丝或其他损伤被发现后，两次检测间的时间间隔也应减小。

If the rope has been overloaded or if non-visual damage is suspected, the intervals between examinations should be reduced accordingly.

如果怀疑绳子曾经超载或有不可目测的损伤，两次检测的时间间隔也应相应减小。

Moreover, the examinations should be carried out when the ropes is put back into service after long periods of standstill.

此外，当绳子在搁置很长一段时间后再次应用，应该实施检测。

If a lifting device has been dismantled and reassembled, the rope must be examined before it is allowed to operate again.

如果提升设备被拆除又重新组装，在允许再次操作前必须得到检测。

5. Survey of removal criteria

拆除标准的概述

A wire rope must be removed if one or more of the following criteria can be satisfied:

有一条或一条以上满足下列标准的绳子必须拆除

1) broken wires断丝

A wire rope must be discarded if the permissible number of wire breaks is reached or exceeded. It must also be replaced when local concentrations of wire breaks occur.

如果断丝的数量达到或超过允许值，钢丝绳必须报废，当断丝局部集中发生也必须换掉。 Chapter 7 covers in detail the subject of the permissible number of wire breaks according to British Standard 6570 and the statutory requirements.根据BS6570和法定要求，关于允许的断丝数目，在第7章中详细的包含。

2) reduction in diameter直径的减小

Reduction in diameter can be caused by abrasion, corrosion or a local failure of the rope core. 直径的减小可能由于磨损、锈蚀或者局部的绳芯失效而引起。

According to B.S.6570 a wire rope should be discarded “when the rope diameter anywhere is reduced to 90% of the nominal diameter in the case of six and eight strand ropes”.

根据BS6570标准，在6股/8股钢绳中，当直径减小到公称直径的90%，钢丝绳应该报废。 Considering the fact that a rope is allowed to have oversize of 4% when new, this figure would allow for a diameter reduction of 14%, which seems to be excessive.

考虑实际情况，新的钢绳有4%的上公差，这一数字允许直径减小14%，这看起来过多。 For multi-strand ropes B.S.6570 recommends a detailed examination “if the rope diameter falls to 97% of the nominal, or rises to 105% of the nominal”, because “discard may be necessary”.

对于多层股钢丝绳，BS6570推荐了一个具体的检测标准：如果绳子直径减小到公称直径的97%或增大到公称直径的105%应该报废。因为“报废是不可避免的”。

3) corrosion锈蚀

Corrosion may be external or internal, general or localized According to B.S.6570, a wire rope should be discarded “when the surface of the wires is severely roughened or pitted, or if the wires are slack within the strands due to wastage. 锈蚀可能是外部的或内部的，整体的或局部的。根据BS6570标准，当表面严重粗糙化或起坑，或者由于损耗引起股内钢丝松动时，钢丝绳应该报废

4) rope deformation绳子变形

a) Waviness. This deformation, while it may not necessarily affect the strength of the rope, can transmit pulsation and produce uneven rope wear. When the rope is laid on a level surface under no load, the maximum height of the “wave” should not be greater than the nominal rope diameter +1/3, otherwise the rope should be removed from the service.波浪型变形。这种变形，虽然不一定影响到绳子的强度，但能传递一个有节奏的震动而产生不平均的磨损。在空载的情况下，水平地放置钢丝绳，“波浪”的最大高度不能高出公称直经的1/3，否则绳子应该拆除。 b) birdcage (basket deformation)鸟笼（“篮状”变形）

A birdcage develops when the outer layer of strands becomes longer than the inner layer or layers. The condition may occur as a result of incorrect fitting, tight sheaves, shock loading，incorrect use of swivel or the application of a heavy load to a new rope before the strands have settled into position. Ropes with a birdcage should be discarded.当外层股变得比内层股稍长鸟笼就产生了。这种情况的发生是由不正确的装配，过紧的滑轮，震动载荷，错误的使用应力释放器，或者在股绳就位之前对新绳施加重荷。绳子有鸟笼状变形应该报废。

c) loop formations“打环”变形

Wires or groups of wires may form a line of loops parallel to the axis of the rope. This deformation is often caused by shock-loading. Loop formations are a justification for discard.钢丝或一组钢丝打成环形成一条线同绳子轴线平行。这种变形通常是由振动载荷引起，“打环”变形有理由报废。

d) loose wires.钢丝松动

Where loose outer wires are found without any adjacent mechanical damage, the most likely cause will be corrosion and the rope should be removed from service. Where loose wires have been caused by mechanical damage, a full examination will decide if the rope can remain in use.

没有邻近机械损伤的外部钢丝松动，这些地方最有可能是锈蚀引起的，绳子应该拆除；受到机械损伤的钢丝松动的地方，判断绳子能否留用要进行全面的检测。

e) nodes节点

A node is a local increase in rope diameter with the core easily visible between several covering strands. It can be caused by shock loading or, in the case of fiber main core ropes, by the absorption of moisture. A node is a justification for discard.

节点是绳子直经局部增大，压在几个股下面的绳芯显而易见。这可能由震动载荷，或是麻纤维芯的吸潮引起的。绳子起节点有理由报废。

f) thinning of the rope绳子直经变细

Thinning is a reduction in the diameter of the rope over a short length.变细是指在一小段距离长的绳子上绳子直径减小。 It is often associated with older fiber cored ropes usually in areas of sustained heavy loads over sheaves.它经常和较旧的、时常在滑轮上持续受重载的区域的纤维芯钢丝绳有关系。 The disintegration and loss of the core can allow one of the covering strands to take the place of the core. “绳芯”的瓦解和麻芯的缺失可以允许一个外部的“绳股”取代“绳芯”的位子。 When this condition occurs in ropes with IWRC the distortion will most often be in the vicinity of the termination away from drum.当这种情况发生在独立钢芯的钢绳身上，扭曲变形最常在远离卷筒的绳子终点附近出现。 The most likely cause is the rope rotation which has allowed the rope to unlay, resulting in the overload and reduction in diameter or failure of the IWRC.最可能的原因是绳子旋转，使绳子退捻，由于超载或独立钢芯失去作用而直径减小。 g) misplaced outer wires外部钢丝错位

Misplaced outer wires are wires forced out of position along the line of the rope to form small flattened loops. This can be caused by bad drum spooling or by the rope being drawn across a sharp edge. Langs lay ropes are often worst affected. Misplaced outer wires are a justification for discard.外部钢丝错位是钢丝沿着绳线方向被挤出形成扁平的圈圈，“同向捻”钢绳通常受此影响最大，外部钢丝错位有理由报废。

h) kinks打圈成节

Deformation caused by a loop in a rope being tightened when the rope cannot rotate about its axis to release the torque. The tight bend or kink thus formed can result in a serious loss of strength due to unbalance in the lay lengths. Ropes with kinks must be discarded.在绳子不能沿着轴线方向旋转而释放扭矩时，绳子上的打圈被拉紧而产生的变形。这样形成的绳节或紧绷的弯曲，由于“捻长”失去平衡会导致一系列的强度损失。绳子打结必须报废。

i) plat areas局部扁平

A flattening can be caused by bending the rope severely over the rim of a sheave or any sharp object with the wires on the inside of the bend being forced out of position. Ropes with flat areas should be discarded.在滑轮的边缘上或者一些尖锐的物体上严重的弯曲可能导致绳子压扁，弯曲一侧的钢丝被挤出位。绳子有局部压扁应该报废。

5) damage caused by heat受热引起的损伤

Heating rope wires to approximately 300?C and over will lead to considerable reduction in tensile strength of the wires. Wire ropes which have been subjected to excessive heat must be discarded.加热绳丝至大约300多度将会导致相当大的强度减小。钢丝绳经常受到过高温度的影响必需

报废。

6. where must wire ropes be inspected or examined?

哪些地方钢丝绳必需进行检验和检测

During an inspection or a periodic examination by a competent person, the full length of the rope should be checked. The following areas may require more detailed attention:在检验或有胜任的人员进行的定期检测过程中，应该检查绳子的全长。下面区域需要更加留心：

a) Rope zone with the highest number of cycles. During normal day to day operations some

section of a rope length will suffer a greater number of bends over sheaves and drums than others. It is in these areas where the greatest number of fatigue wire breaks can be expected. 绳子弯曲周期最高的区域。在常规日复一日的操作中，比起其它地方，在卷筒和滑轮上有一部分绳长将会承受更多的弯曲次数，在这些疲劳弯曲最多的地方断丝会被检出。 b) Pick-up points. When a lifting device picks up or releases a load with same sections of rope

regularly in contact with sheaves and drums, those sections of the rope are subjected to increased stress.承载点位。当提升装置用和滑轮/卷筒有规律接触的不变的那部分绳子去承载或释放一个载荷时，这些部分的绳子受到增大的压力。

c) Ending fittings. At, or closely adjacent to, terminal fittings the elasticity of the rope is

restricted and the geometry “frozen”. Depending upon the type of fitting, there will be additional pressure on the rope and the section close to the area of contact between rope and fitting is often the focal point for increased stress caused by vibration. The damage of corrosion is also increased by the retention of moisture in the area of contact between rope and fitting.末端连接配件。在末端配件或非常邻近末端配件的地方，绳子的弹性受到限制和几何学上的“冻结”。基于不同的配件类型，会有一个附加的压力作用在绳子上，这些接近绳子和配件接触区域的绳子部分，常常是震动导致压力增大的焦点。在这些绳子和配件接触的区域，由于潮湿的阻滞，锈蚀损伤也增大。

d) Equalizing sheaves. Ropes which are often considered to be stationary around equalizing

sheaves can be subjected to hight numbers of bend cycles caused by the uneven spooling of two drums, by swinging loads or by frequency vibrations. As the rope might never leave the equalizing sheave, moisture can be trapped in the area of contact between rope and sheave and cause corrosion.平衡轮。绳子通常被认为固定的绕在平衡轮上，由于载荷的摇摆或频繁的震动而导致两个卷筒上不平衡的卷绳，平衡轮上的绳子常遭受很高的弯曲周期数，因为绳子可能总是不离开平衡轮，潮湿可能被截留在绳子和滑轮接触的地方导致锈蚀。 e) Zones of maximum wear on drums. Pick-up points and cross-over points on the drum are

subjected to increased wear and therefore require special attention. Misplaced and broken wires caused by scrubbing can be expected at cross-over points. The damage can be severe where the fleet angle in excessive. With multiple layer spooling, the first layer of rope on the drum should be tightly wound to provide a firm base for subsequent layer. This applies in particular to plain drums and parallel grooved drums, e.g. Lebus.Slack winding or lateral movement between turns of rope will affect the spooling of subsequent layers and can cause damage. The point where the rope is squeezed between the drum flange and the previous turn as it rises to commence the next layer, is an area of accelerated wear and should be given special attention.卷筒上磨损最大的区域。卷筒上的承载点和交叉跨越点钢丝绳常常遭受增大的磨损，因此要求特别留心。在交叉跨越点由于磨擦引起的钢丝错位和断丝有希望

被检查到。在穿绳入角太大的地方钢丝绳损伤可能会很严重。多层卷绳中，卷筒上第一层应该收紧为后面层提供一个牢固的基础。这种情况特别适用在平卷筒和像Lebus.Slack卷绳的开平行绳槽的卷筒，或者绳圈间横向运动会影响到下一层“卷绳”并导致损伤的卷筒。在绳子受到前一圈绳子和卷筒边缘挤压并上攀至上一层的这一点，是加速磨损的区域需要特别留心。

f) Sheaves. Sheaves should be examined for general condition and tested for freedom of

movement. Using a groove gauge the tread radius can be measured. The radius of the grooves should be equal to the nominal rope diameter plus 6% to 10%. Undersize grooves will seriously reduce the service life of the rope due to premature fatigue caused by insufficient support in the groove area. Where the rope surface pattern is imprinted into the sheave tread, the sheave should be replaced.滑轮应做常规条件的检查并测试活动是否自由。用量槽量规可以测得槽底面半径。绳槽底半径应是绳子公称直径+6%-10%，较小的绳槽直径因为不充分的槽面支撑而导致过早的疲劳，将严重地减少绳子的服务期。绳子表面纹路在槽底形成压痕，滑轮应该换掉。

g) Rope sections working in a hostile environment. High temperature can considerably reduce

the breaking load of a wire rope. Temperature of up to 250℃ will not affect the tensile strength of the wire, but temperature of only 50℃ can cause leaching of the rope lubricant. The consequent severe wire to wire friction will result in a marked reduction of rope performance. The exposure of rope to chemical action can greatly increase the effect of corrosion. In each of the areas where wire breaks or other defects are found, the number and description with the location, must be recorded.工作在不利环境中的绳子部分。高温能减少相当大的钢丝绳破断载荷。温度达到250摄氏度不会影响钢丝的抗拉强度，但只要50摄氏度的温度就能导致绳子润滑脂流失。随之而来的钢丝和钢丝之间的摩擦将导致绳子性能的显著降低。暴露的绳子受到化学反应大大地增加了锈蚀。在哪些有断丝或者其它缺陷被发现的每一个地方，断丝的数量和断丝部位的描述必需被记录下来。

7. Discard number of wire breaks

达到报废的断丝数量

The Construction (Lifting Operations) Regulations requires a rope to be replaced when the number of broken wires reaches 5% of the total number of wires in the rope in 10×d. the Factories Act, The Shipbuilding and Ship-repairing Regulations and the Offshore Installations Regulations do not specify a particular number of broken wires for discard and leaves this decision to the discretion of the examiner. The Health and Safety at Work Act requires the provision and maintenance of plant and systems of work that are, so far as is reasonably practical, safe and without risks to health. The table on page 25 shows the recommended number of discard wire breaks for Casar special wire ropes. For the number of discard wire breaks in other types of multi-strand ropes the user is advised to contact the rope manufacturer. Depending on the factor of safety, the assessment of broken wires in 6 and 8 strand ropes working over steel sheaves is divided into two groups:

建筑（起升操作部分）规范规定10倍绳子直径内断丝数量达到钢丝总数的5%要求换掉。工厂法，船舶制造和船舶维修规范以及岸桥吊安装规范对于报废没有指定详细的断丝数量，把这个问题留给检测者判断。工厂健康和安全法要求进行系统的工厂防范和维护，就是只要是相对适用，安全以及不危害健康。25页的表给出Casar特殊规格钢丝绳推荐的达到报废标

准的断丝数目。对于其它类型的多股钢丝绳达到报废标准的断丝数目，建议用户同绳子的制造商联系。基于安全系数的考虑，用在钢质滑轮上的6股绳和8股绳的断丝数目的评估分成以下两组：

1) Factor of safety less than 5: 5% of the number of outer strand wires excluding filler wires. 安全系数低于5倍：包括填充钢丝在内的“外层股”的钢丝总数的5%

2）Factor of safety greater than 5: 10% of the number of outer strand wires excluding filler wires 安全系数高于5倍：包括填充钢丝在内的“外层股”的钢丝总数的10%

When broken wires are detected, the number and position, along with the examiner’s opinion of the general rope condition, will decide whether or not the rope should be discarded. If local concentrations or groups of broken wires are found, the rope should be discarded when:

当断丝被发现，断丝的数量和位置连同检测者对绳子总体情况的判断，将用来决定绳子是否应该报废。如果断丝在集中的局部地区或者成群的被发现，绳子应该根据下列情况报废： a) Three or more broken wires are found in the close proximity of the termination.

三根或三根以上的断丝出现在紧靠绳子端点的地方

b) Three or more broken wires are found in one strand or

在一股内发现三根或三根以上的断丝

c) Five broken wires are found between two adjacent strands within a length of 10×rope

diameter

10倍绳子直径的长度内，相邻两股中有五根断丝被发现

If the number of broken wires doe not justify discard, the position and number of all broken wires found must be recorded in the rope Log Book. When broken wires are found in close proximity to a permanent termination, such as a white metal or resin secured socket and the general condition of the remainder of the rope is acceptable, it may be decided to cut the rope and re make the termination. In such cases it is recommend that the socket is submitted for N.D.T. and heat treatment. Care must be taken to ensure sufficient turns of “dead” rope remain on the drum after the termination has been remade.如果断丝数目不足以判断绳子报废，所有断丝的数目和位置必需被记录进绳子记录簿。如果断丝在非常接近永久性的终端，如白合金或树脂固化的索节，而且绳子剩余部分的总体条件还可以，可能决定切掉绳子，重做一个绳端。在这种情况下建议对索节做N.D.T.（无损伤试验）和热处理。在绳端重做后，必须小心确保卷筒上保留足够的“死”圈。

8. Rope examination procedure

绳子检测过程

8.1 equipment器材

In order to carry out a proper inspection, the following tools should be available:

为了实施正确的检测，下列工具应该提供：

A list of discard criteria (this manual)一份标准清单（本手册）

A rope caliper or vernier gauge一把卡钳或者游标卡尺

A steel tape一把钢卷尺

A piece of white chalk一支白粉笔

A wax pencil (dark coloured)一支蜡笔（黑颜色的）

A roll of adding machine paper一卷阿基加纸

A sheet of typing carbon paper一张打印纸

A screwdriver一把螺丝刀

A magnifying glass一只放大镜

A pencil一支铅笔

A roll of marking tape一卷标记带

Two sets of groove gauges两套绳槽量规

A piece of cleaning cloth一块干净的布

A wire brush一把钢丝刷

A pair of gloves一副手套

A note book or an inspection form一个笔记本或检测表

The previous inspection records 之前的检测记录

8.2 locating of wire breaks查找断丝的地方

Identification of wire breaks can by visual and physical examination or by the use of electromagnetical equipment. The first step in wire rope examination is to find the rope section with greatest concentration of wire breaks. This is normally done by first visually inspecting the full length of the rope.

鉴定断丝可以通过目测和物理检测或者通过使用电磁设备检测。钢丝绳检测的第一步是找出断丝最集中的区域。这通常是先目测绳子全长来完成。 In some cases it can be helpful to spool the rope slowly through the hand. Special attention has to be paid and strong protective gloves must be worn. A piece of wood held on the surface of a moving rope will be deflected by the protruding ends of broken wires. In the same way, a soft cotton or similar type cloth held against a moving rope will be caught by protruding ends and thus detect the broken wires. Smooth synthetic material is less suitable for this purpose.

有些情况下，穿过手心慢慢地卷绳将有助于发现断丝。特别注意必须带上牢固的防护手套。握住一片木头放在运动的绳子上，经过断丝末端的突出部分木头会偏离。同样的办法，柔软的棉花或类似的布匹握在手中，靠在运动的绳子上会被突出的末端钩住，这样就发现了断丝。平滑的合成材料不太适合这种用途。

The detection of broken wires in the strand valleys can be difficult. The use of a scraper or piece of shaped wood will help clean out the valleys. The use of a wire brush on a dirty, heavily lubricate rope can loosen, but not always remove, old lubricant and the brush may have to be cleaned frequently with a solvent. Where solvents are used to clean the rope surface, they should be used sparingly and the rope section should be thoroughly lubricated afterwards. A light lubricating oil used with a wire brush is preferred for softening old lubricant which can then be wiped off with a cloth. When the worst affected sections of rope have been found, their boundaries should be marked by chalk or tape for further examination.

在股绳的凹处发现断丝是困难的。用一把刮刀或像刮刀一样的木片将有助于清除凹处的垃圾。在一根脏的涂上很厚油脂的绳子上使用钢丝刷，能使旧的油脂变松，但不是总能使油脂带走，刷子可能不得不用溶剂频繁的清洁。用溶剂清洁绳子表面的地方，溶剂应节约地使用，然后这些绳子部分应该彻底润滑。用钢丝刷涂上少许润滑油，首先使旧的油脂软化，然后可以用布擦去。当受到影响最坏的绳子部分被找出，它们的边界地方应该用粉笔或胶带做好标记以便进一步的检测。

A gauge should be set to a length of 10×d. this can now be moved within the boundaries to locate the section with the maximum number of wire breaks. The breaks in 10×d should be counted and entered in the records. With thin ropes, valley breaks can be detected by strongly flexing the unloaded rope.

标准尺的长度应设定为10倍绳子直径的长度，这样，现在可以移开尺子，在边界线内查找有最大断丝数的部分。10倍绳子直径内的断丝数应该计算出并输入记录中。细的绳子，股绳凹处的断丝可以通过用力地弯曲卸掉载荷的绳子来察觉。

8.3 determination of the rope diameter判断绳子的直径

The rope diameter should be measured on receipt for conformity with the specification. British Standard (B.S.302:1987, Stranded steel wire ropes, Part 1. Clause 5.1) allows for a tolerance of -1% to +4% of the nominal rope diameter.

绳子的直径应该根据收到的相应的标准进行测量。英国标准（BS302：1987，圆股钢丝绳第一部分5.1条款）允许钢丝绳的公称直径有-1%到+4%的公差。

The generally accepted method of measuring rope for compliance with the Standard is to use a caliper with jaws broad enough to cover not less than two adjacent strands. The measurement must be taken on a straight portion of rope at two points at least 1 meter apart. At each point two diameters at right angles should be measured. The average of the four measurements is the actual diameter. After the rope has made the first few cycles under low load, the rope diameter should be measured at several points. The average value of all the measurements at each point must be recorded and will form the basis of comparison for all future measurements. The measurement of the rope diameter is an essential part of all inspections and examinations. It ensures the maximum diameter reduction does not exceed the recommended figure. As stated in 5.2. British Standard 6570 recommends that a wire rope should be discarded when the diameter of the rope reduced to 90% of the nominal diameter.

依据标准，一般认可的检测方法是用一个宽口足以覆盖不少于相邻两个股以上的卡尺。测量的应该是绳子的直的部位两个点，两个点相距不少于1米。每个点的直径量两次，第一次量好后，转动90度再量一次。四次测量值的平均数就是绳子的实际直径。绳子在低载荷下经过最初一些弯曲周期后，应该在多个点测量绳子的直径。每个点测量下来的所有值的平均值必须记录下来为将来的测量形成一个进行比较的基础 。绳子直径的测量是检验检测最基本的一个部分。它确保最大的直径缩小不超过推荐的数字。按照英国标准BS6570 5.2条款的规定，当绳子直径减小到公称直径的90%，建议绳子应该报废。

A comparison of the measured data with the recorded previous values can detect an abnormal rate of reduction in diameter. Coupled with assessment of previous examination data, the probable date of renewal can be predicted. If we examine the cross-section of a six-strand rope, we will find that measuring the thickness of the rope over the crowns will produce a higher value than measuring it over the valleys. The actual diameter of the rope is defined as the diameter of the circumscribing circle.

把测量的数据和以前记录进行比较可以发觉不正常的直径减小速率 。加上对以前检测数据的评估，就能预知大概的换绳日期。如果我们检测一根6股绳的横截面，通过绳子冠部（crowns）量的厚度值比通过绳子凹部（valleys）量的厚度值高得多。实际的绳子直径定义的是沿着绳子四周画的圆的直径。

When using a conventional caliper, wire ropes with an even number of outer strands (four-, six-, eight-, ten-, and multi-strand) ropes must be measured from crown to crown. The advantage of a proper wire rope caliper with measuring plates is that even if the measurement is carried out “incorrectly”, adjacent crowns are always included, so that the actual diameter is determined at any section (fig.10)

.使用常规的卡钳，钢丝绳的外层股数是偶数的必须冠部到冠部的测量。适合钢丝绳直径测量的卡钳带有测量平板，优势是即使实施了“不正确”的测量，相邻的冠部总能包括进去，

因此能测定任何部位的实际直径。

Measuring the diameter of wire ropes with an uneven number of outer strands (three-, five-, seven-, or nine-strand ropes) is more complicated: a crown on the one side of the wire rope always has a valley as a counterpart on the other side of the wire rope. A conventional caliper, therefore , has to be applied diagonally to the axis of the rope, so that at any time a crown adjacent to a valley is covered. Again a wire rope caliper with measuring plates is definitely to be preferred as it always includes strand crowns. In all cases during periodic examinations where the measurements are to be recorded, the rope should be measured as already described. Where the “roundness” is being checked to detect potential faults, two diameters, one at right angles to the other can be taken and noted in the records. The entry into the records might read “Rope diameter:20.4/20.5mm”

测量外层股数是奇数的钢丝绳的直径更加复杂：在绳子一边的冠部总会有一个对应得凹部在绳子另一边。运用常规的卡尺必须和绳子轴线成对角状测量，这样无论什么时候与凹处相邻的冠部被卡到。.定期检测中，绳子应该像前面已经描述的那样进行测量，所得测量结果将被记录下来。为了发觉潜在的缺陷，将检查绳子的“圆度”，测量直径两次，两次相对转动90度，结果写进记录。输入的记录可以读作“绳径20.4-20.5mm”.

8.4 measuring rope lay测量绳子的捻距

After a rope has been fitted to the appliance, its length cannot be measured again accurately without a great deal of trouble. The purpose of measuring the length of lay is to detect any increase in the rope length which may have been caused by corrosion, core deterioration or rope rotation (unlaying). With a new rope the wires and strands should be allowed to settle into their permanent position. Six or seven lifting cycles with a light to medium load are recommended before measuring the lay of the rope. To minimize error, the measurement should be made over four lays and the length divided by four to find the average lay length.

当绳子已经配备到设备上后，不费一番大力气，它的长度不可能再被精确地量出。测量绳子“捻距”的目的是为了发觉绳子的增长，这种增长可能由侵蚀，“绳芯”的退化或绳子旋转（退捻）导致。新绳子中钢丝和股绳会被认为安置在永久性的位子。在测量绳子“捻距”前，建议在轻载或中等载荷下提升6到7个周期。 为了使误差最小化，测量4倍“捻距”的长度，然后除以4求得平均捻长。

On eight strand ropes the eight, sixteenth, twenty fourth and thirty second strands must be marked. Using a strait length of the rope and with the rope under no load, first mark any strand on the crown with a piece of chalk: this strand now becomes “crown zero”. Excluding this strand, count the next eight strands and mark the eighth strand with chalk. Exclude the eighth strand and repeat this procedure a further two times. The measured length between the outer chalks marks is then divided by four to give the lay length.

“8股绳”第8，16，24，32股必须做上记号。在绳子不受载荷的情况下，取笔直的一段绳长，首先用粉笔在任意一股的冠部做上标记，这一股现在就成为“冠0”。除去这一股数到下面第8股，用粉笔做上标记。除去第8股，重复这个过程再做两次。量得外面的两个粉笔标记间的长度，然后除以4得出捻距。

As a rough check on the overall accuracy of the chalk marking, the length of lay for eight strand ropes is approximately between 6.25 and 6.5×the diameter of the rope e.g. using a lay length of

6.5×rope diameter, four lay length of a 32mm diameter rope will be 32mm*6.5*4=832mm. 相对全面精确的检测，粉笔做标记只是粗略的检查，“8股绳”的捻距大约在绳子直径的

6.25-6.5倍之间。例如用6.5*绳子直径求捻距，32mm直径的绳子，4倍的“捻距”就是

32mm*6.5*4=832mm.

An alternative method of measuring the rope lay is to secure the free end of the roll of adding machine paper to the rope with adhesive tape. The paper is rolled out over the rope and simultaneously the wax pencil in drawn over the paper, providing a clear print of the outer wires of the rope. The finished print can be filed for comparison with later measurements. A third method is to wrap typing carbon papers round the rope under the roll of paper. by rubbing along the paper with a piece of cardboard, the carbon marking on the underside of the paper can be confined to the tops of the strand crowns.

另一种测量捻距的方法是把卷状的阿基加纸的自由端用胶带缠在绳子上，纸张顺着绳子上面滚出，同时蜡笔从纸上描过，给出了绳子外层钢丝的清晰的印痕。描绘好的印痕可以归档，用于同后面的测量结果做比较。第三种方法是在卷纸的下面，沿着绳子缠上一圈渗碳打印纸，用一片硬纸板在卷纸上擦，纸张内侧复印的印痕被限制在股冠部顶部。

8.5 checking the stability of the rope检查绳子稳定性

A rope in good condition will have all strands tightly laid. A screwdriver inserted between strands when twisted, should meet with stiff resistance. If the screwdriver can be twisted between different pairs of strands without much resistance, a full examination should be carried out. The unskilled use of a screwdriver or Marlin Spike to examine the rope core can cause serious damage to the rope.

良好状态的绳子所有的股是牢牢的捻制在一起的。螺丝刀插入两个螺旋股间，将受到僵硬的抵抗力。当螺丝刀在不同的几对股绳间不受太大的抵抗力而扭动，绳子应该全面实施检测。非专业的使用螺丝刀或Marlin Spike（解缆钻）检测“绳芯”可能导致对绳子严重的伤害。

8.6 changes in rope structure绳子的结构变化

In addition to the examination areas detailed in section 4, deformation caused at any point in the main working area can move along the rope. Waviness, and in particular, a birdcage can be moved along the rope by the action of the sheaves. A degree of slackness in the outer cover of a multi-strand rope may not be sufficient to form an immediate birdcage. However, slackness can be “squeezed” along the rope. With the normal length of rope out any slackness in the outer cover will usually be found at the end termination or where the rope meets the drum.

除了第4部分详细讲述的检测区域，主要工作区域任何一点导致的变形可能沿着绳子向前移动。波浪形，特别是鸟笼形，能够通过滑轮的运行而移动。多层股钢丝绳的外层股有一定程度的松弛，可能不足以立即形成鸟笼状，然而，这种松弛会被挤压沿着绳子跑。就绳子的常规长度而言，在“外层股”上的一些松弛，通常在绳端或绳子和卷筒连接的地方被发现。

8.7 inspecting sheaves and drums检测滑轮和卷筒

Remarks in this section are intended to apply equally to sheaves and drums.这一部分的解释旨在滑轮和卷筒的应用。 A tight groove in a sheaves or drum will subject the rope to enormous radial pressure. Rapid deterioration and premature wire failure, particularly in the valleys between strands, can be expected（fig.11.a）On the other hand a wide groove will not provide essential support to a rope under load. Oval shaped deformation is produced resulting in uneven distribution of the load between individual wires with consequent early failure（fig.11.c）.

滑轮和卷筒上过紧的绳槽将使绳子受到巨大的径向压力，特别在股绳间的谷部，迅速的退化和过早的钢丝失效有望被检测出来。令一方面太宽的绳槽在载荷下不能给绳子基本的支撑，个体钢丝之间的载荷分布不均导致椭圆形变形，随之而来的是钢丝过早的失效。

Sheaves can be checked with gauges which are available on the open market. The use of specially made circular templates is preferred. The recommend size for a sheave gauge is the nominal rope

diameter +6% to +10%（fig.11.b）. In order to establish the size of a sheave groove, templates for the sizes above and below the recommended size will be required.

滑轮可以用市场上可以买到的量规进行测量。特制的圆形模板是首选的。推荐的滑轮标准尺的车寸是绳子公称直径的+6%到10%。为了确定滑轮槽直径，用作量尺的模板，尺寸高于推荐尺寸和低于推荐尺寸的都得有。

The sides and tread of sheaves which have been in use for some time are often heavily coated with old lubricant, some of which may first have to be removed with a scraper. By inserting the template as far as possible and drawing it through the remaining lubricant, the fit of the template relative the sheave tread can be assessed. The correct template should be in contact with the sheave tread for about 130°. If the template only touches the side flanges, the groove is too tight. If the template touches only the bottom part of the tread, the groove is too wide.

滑轮的侧面和踏面用过一段时间常常会覆盖上厚厚的旧油脂，有些油脂首先必须用刮刀刮去。通过尽可能地插入模板并透过残余的润滑脂，对应滑轮踏面的合适的模板可以先估定。正确的模板和滑轮踏面的接触大约是130度。如果模板只是接触旁边的法兰，绳槽就太紧；如果模板只是接触踏面的底部，绳槽就太宽。

Attention should also be given to the flanges of the sheaves. Absence of lubricant, scratching or unexpected wear on one side will indicate (a) misalignment of the sheave and (b) the danger of torque being induced into the rope due to the rope rolling down the flange into the tread. The tread should be cleaned and carefully examined for any sign of ridging or imprinting. In the case of imprinting with the rope profile the rope in service may have caused the damage and is unlikely to be seriously affected. A replacement rope will not fit exactly into the imprint and will suffer serious damage during the early part of its service.

滑轮的法兰也应给予注意。油脂的缺失，划痕或单边上意想不到的磨损预示着：a.滑轮没对准b.由于绳子从法兰上滚着向下进入踏面，扭矩有被引导进入绳子的危险。踏面应该清理干净，仔细检查是否有起皱或压痕。在有绳子轮廓压痕的情况下，在用的绳子会引起损伤，但受到的影响未必是严重的。换上去的绳子不会严密地适应这些压痕，在它服务期的早期时候会遭受到严重的损伤。

When a rope change is made, the sheaves should be checked for eccentricity and the bearing for wear and free running.

换绳的时候，滑轮要做偏心检查，还有轴承有否磨损，是否运转自由。

9. electro-magnetic wire rope examination钢丝绳电磁检测

After a period in service surface wear and/or a number of wire breaks will indicate the rope condition has deteriorated and discard may be imminent. Specific working conditions however, may lead to internal wire breaks and to internal loss of metallic area. It may be surprising to learn that this in particular applies to ropes which, for safety reasons, are operated with large diameter sheaves and high factors of safety. Dynamically loaded ropes or ropes which are subjected to torque when working, can suffer from internal wire breaks caused by overstrained interior rope elements. In addition, when the reeving system includes sheaves lined with plastic or all plastic sheaves, these sheaves offer more elastic support than steel sheaves. The pressure between outer wires and the sheave grooves can be reduced to such an extent that with some rope constructions the first wire breaks will occur, not on the surface, but within the rope. In all these cases electro-magnetic testing will allow non-destructive examination and appraisal of the rope’s internal condition.

经过一段时间的使用后，表面的磨损和一定数目的断丝会显示绳子情况已经退化，报废即将到来。然而，特定的工作情况导致内部断丝和内部的金属截面积损失。这种情况特别会出现

在，那些被认为是安全的，运行在高安全系数大直径的滑轮上的绳子身上。了解这点可能令人很惊讶。受到动载的绳子或者在运行中受到扭矩的绳子，会受到绳子内部因素应变过度导致的内部断丝的伤害。另外，当穿绳系统包含的滑轮和塑料滑轮或者全部是塑料滑轮穿在一起，这些滑轮同钢质滑轮相比提供了更大的弹性支撑。外层钢丝和滑轮槽之间的压力会被减小到某一范围，在这一范围内，某些结构的绳子发生最初的断丝，不是在表面，而是在绳子内部。 所有这些情形电磁检测仪允许进行非破坏性的检测，给绳子内部条件进行评估。Electro-magnetic testing equipment available on the market allows-depending on individual design-indication or continuous recording of localized damage such as single broken wires, breaks of strands, soldered and welded joints as well as wire pitting and even detection of reduced metallic area caused by corrosion over the whole rope length. The data are plotted as a function of the rope length, which is continually, measured either during the inspection or, if a recording is done, during the following analysis. In this way every signal on the recording can unmistakably be related to a zone on the rope.

市场上提供的电磁检测仪，依据个体设计，允许显示出或连续地记录下局部化的损伤，像单纯的断丝，断股，焊接，还有钢丝的蚀损斑，甚至整个绳子长度上由锈蚀引起的金属截面积的减小。数据随着绳长以函数形式绘出，这些数据是在检测过程中连续地测得，或者记录已经完成，在随后的分析中得出。这样记录上的每一个信号都能明确地描述绳子上对应区域的情况。

This method allows a more precise visual inspection of those sections of the rope which showed exceptional inconsistencies during the electro-magnetic inspection. Furthermore, recording the data during regular electro-magnetic inspections makes it possible to compare the results with previous recordings. In this way the advance of the deterioration of the rope can be ascertained.

这种方法允许对电磁检测过程中显得异常的那些地方进行更精确的目视检测。而且在常规的电磁检测过程中记录下来的数据，可以用来同之前的记录结果进行比较。这样可以探知绳子的提前退化。

Electro-magnetic testing equipment for wire ropes was already being developed at the beginning of the 20th century. Only very few specialists could use the equipment properly but over the past few years the use of these instruments has been greatly improved so that they are now at the command of a much wider range of users. It is likely that within a few years there will be equipment on offer which not only records measured data but also - by means of a micro computer – will process the data with regard to amplitude and frequency will provide the examiner with data such as frequency curves and the accurate assessment of the reduction in breaking strength.

钢丝绳电磁检测设备在20世纪初得到开发，只有很少数的专家可以正确地使用，但经过短短几年，这些设备的使用已经大大的改进，因此，现在被广大的用户所掌握。很可能几年内将有出售，不仅用来记录测量数据，而且通过微型计算机处理关于振幅和频率的数据，

At the moment instruments are being developed which, apart from the data mentioned above, can also record the rope diameter and the lay length of the rope. This will enable them to register out-of-roundness of the rope diameter, corkscrew-like deformations or changes of the lay lengths along the rope length. For inspection a test head is clamped around the rope. Then the whole length of the rope is pulled through the test head. If this is not possible, as in the case of suspended ropes of rope ways, the test head is drawn along the wire rope. During this procedure all test data are transmitted via cable or radio to an amplifier. The test data are indicated either optically or acoustically recorded on magnetic tape or represented graphically during the test. An electro-magnetic test instrument is shown in Fig.14.

现在设备还在发展中，除了上面提到的数据外，还能记录绳子的直径和捻距。这使它们能够记录绳子直经的“不圆度”，丝锥状变形或者整个绳长的“捻距”变化。检测的时候一个测试头被环绕绳子夹住，然后整根绳子通过测试头拉过。如果这种情况不可能，比如像索道钢丝绳，测试头沿着绳子拔过。在这个过程中，所有测试数据通过电缆或者无线电传输到一个放大器。测试过程中记录在磁带上或呈现在绘图上的测试数据被有声有色地显示出来。电磁测试仪见图14。

Calibration of the testing equipment requires great care. A recommended method of checking the function and accuracy of the equipment is to attach lengths of wire, having diameters equal to the largest and smallest sizes in the rope, along the first meters of rope length. By means of sellotape these wires can be secured in the strand valleys. At the beginning of the recording strip chart the examiner will obtain reference data indicating the size of the amplitudes of the test wires.

校准检测设备需要特别小心。一种推荐的检测设备功能和精确度的办法是，顺着绳长的最初几米内附上一定长度的钢丝，钢丝的直径和绳子内最大的钢丝直径和最小的钢丝直径相等。通过透明胶带这些钢丝可以被封牢在股绳间的谷里。在带状纸记录的开始部分，检测者可以得到被检绳子显示出来的振幅大小的参考数据。

Fig.15a illustrates a typical diameter of a rope section with wire breaks. Fig.15b shows the recording of a rope section affected by corrosion. Selecting the suitable test instrument, competent handling and the correct interpretation of the data require a lot of experience and expert knowledge. Various universities, test institutes as well as commercial firms, render electro-magnetic inspection of wire ropes as a service. The discard numbers of wire breaks specified in the Standards refer solely to external wire breaks. Appraising the condition of the wire rope with regard to internal wire breaks is therefore left to the inspector; he would be well advised to discard a wire rope when the total number of external and internal wire breaks, added together, reaches the discard number of wire breaks specified in the Standards.

图15a 阐明了一个典型的钢丝绳断丝截面。图15b显示了一个受到锈蚀影响的截面记录。选择适当的设备，胜任的人员处理和对数据的正确阐释需要很多的经验和专业知识。许多院校，检测机构，还有商业公司都提供钢丝绳电磁检测服务。标准里指定的达到报废的断丝数目单单是指外部断丝。因此关于有内部断丝的钢丝绳条件的评估留给了检测者，当外部断丝和内部断丝加在一起达到标准内指定的断丝数目，他就会认真地考虑报废钢丝绳。 Electro-magnetic tests can not, and must not, totally replace visual inspections. Yet, they provide valuable additional information on the conditions of wire ropes and must be regarded as a useful addition to the visual inspection.

电磁检查不能，也不可能完全取代目视检测，但是他们提供了钢丝绳条件评估的颇有价值的附加信息，将被看着对目视检测的有用的附加设备。