Research and development

A well thought-out development and selection of steel cables for industrial applications requires a comprehensive understanding of design, material, tolerances and rope end connections. All factors must be considered in combination, in order to optimise the desired mechanical properties, service life and performance of the wire rope for the respective application. Properties such as rope resilience, tensile strength of the steel wire ropes and others are guaranteed by the targeted selection of the steel cables.

1. selection of design and construction: Selecting the right rope construction is the first step in ensuring that the wire rope meets the requirements of the application. Wire ropes differ in their construction, the number and arrangement of the strands and the wire diameter of the individual strands. Flexibility and stability are particularly important for small diameters (0.09 mm to 8 mm). Two main categories play a role here: 1x7 or 1x19 strands are constructions with higher tensile strength but lower flexibility, and ropes with a multi-strand structure such as 6x7-WSC or 6x19-WSC are constructions characterised by higher flexibility. For applications that require a high degree of flexibility, such as robotics, multi-conductor rope constructions are advantageous. There are also special constructions such as compacted ropes for special requirements in medical technology.
2. selection of the right wire rope material: The material not only influences the mechanical properties, but also the resistance of the wire rope to environmental influences. Commonly used materials are stainless steel 1.4401 - AISI 316 or 1.4301 - AISI 304 and galvanised carbon steel. Stainless steel offers excellent corrosion resistance and is therefore suitable for applications in corrosive environments, such as in medical technology or outdoors. Galvanised steels, on the other hand, have high strength and are more cost-effective. For special requirements, high-strength alloys such as Inconel, titanium or tungsten can also be used, e.g. for high-temperature applications or when anti-magnetic properties are required. The choice of material must always take into account the required tensile strength of the steel wire rope, service life and environmental conditions.

3. selection of the required tolerance: The selection of the correct tolerance is a central point for the functionality and precision of wire rope applications. Both the rope tolerances (rope dimensions) and the tolerances of the rope assemblies (connections, etc.) must be carefully considered. Rope tolerances play a particularly important role in precision engineering, robotics and medical technology applications. In the small and micro range (0.09-8 mm), the diameter, roundness and surface quality must be precise, as they affect the function and accuracy of fit. In addition, the final processing must also be precisely adjusted to ensure the function of the overall system. Incorrect tolerances in the cable assemblies can lead to connection problems, power transmission losses or mechanical defects. The length accuracy of the assembled ropes is particularly important when the ropes are used in control systems or actuators, for example, where lengths accurate to the millimetre are crucial for the function.
4. selection of the rope end connector: The rope end connection is of great importance for the safe transmission of force and the integration of the wire rope into the overall construction. Depending on the requirements, various end connections such as thimbles, compression clamps, threaded sleeves or zinc die-cast connections can be selected. For high-precision applications, e.g. in medical technology, clean processing of the end connections is crucial in order to prevent cracks or material fatigue. For applications with dynamic loads (e.g. in robotics), fixed connections with special damping elements are useful to absorb vibrations. The choice of material for the end connection must also be matched to the rope material in order to prevent electrochemical corrosion. Compliance with manufacturing standards must also be ensured here in order to guarantee consistently high quality.