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