The wire rope test is made easier and more reliable through ABUControl, which displays wire rope sections for which pronounced wear has been calculated.
For this work step, access from a laptop or tablet computer to KranOS is necessary. The user "Abnahme" (commissioning) (user level ‚[2]) must be logged in.
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Danger due to a suspended load falling! ABUControl only offers the calculated wear and cannot take into account all operating conditions or any unforeseeable externally caused damage. The wire rope can therefore also have reached its maximum acceptable wear even if ABUControl has not indicated this. Carefully inspect the wire rope in its entirety, regardless of the ABUControl calculation. |
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Overview: Navigation in KranOS |
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User "Abnahme" (commissioning) à "Hoist" à "Wear maximum acceptable wear" From program version 1.2.0.1 |
Log in as user "Abnahme" (commissioning) (user level [2]) in KranOS.
See Connecting laptop or
tablet computer with ABUControl, page .
Select the desired hoist (e.g. Hoist 1) in the main menu.
● The window for the requested hoist appears.
Click on the "Wear maximum acceptable wear" menu item in the
"Settings" menu (gear wheel on yellow background).
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"Rope position" column |
"Wear length" column |
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"Total length wear area" field |
"Maximum wear" field |
● The window "Wear maximum acceptable wear" appears.
● The table shows one or more wire rope sections (one wire rope section per line) for which ABUControl has calculated pronounced wear.
─ The "Rope position" column indicates where the respective wire rope section is located. The length is measured from the fixed point to the start of the respective wire rope section.
─ The "Wear length" column shows the length of the respective wire rope section exhibiting pronounced wear. This is measured from the start of the position given in the "Rope position" column.
● The "Total length wear area" field shows the wire rope section from the table that has been calculated as the wire rope section with highest wear.
● The "Maximum wear" field indicates the degree of wear on the wire rope section with highest wear.
Start the inspection of the wire rope at the displayed rope
positions.
All displayed wire rope sections should be checked in succession. This is where broken wires are expected to appear first.
See next section.
The two left columns "Rope position" and "Wear length" as well as the fields "Total length wear area" and "Maximum wear" are identical to program version 1.2.0.6.
Additional columns:
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Additional columns |
"Status" column |
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● Up to version 1.2.0.5, the window "Wear maximum acceptable wear" shows several additional columns. These do not need to be factored into the evaluation of the maximum acceptable wear.
● The "Status" column gives status information on the wear of the respective line:
─ Status 0 (green): The wear in this wire rope section is below 80%.
─ Status 1 (red): The wear in this wire rope section is below 80%, but higher in all other wire rope sections.
─ Status 2 (red): The wear in this wire rope section is above 80%.
─ Status 3 (red): The wear in this wire rope section is at 100%.
Additional window:
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Overview: Navigation in KranOS |
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User "Abnahme" (commissioning) à "Hoist" à "Wear maximum acceptable wear" à "Deflection rollers maximum acceptable wear" From program version 1.2.0.1 to program version 1.2.0.5 |
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● Up to version 1.2.0.5, the window "Deflection rollers maximum acceptable wear" is available, in which data on individual deflection rollers is displayed in relation to the calculation of the maximum acceptable wear. This does not need to be factored into the evaluation of the wear.
The wire rope sections with pronounced wear have been read in the window "Wear maximum acceptable wear".
On all displayed wire rope sections with pronounced wear:
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Distance from the fixed point up to the start of the wire rope section ("Wire length" field) |
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Wire rope section ("Total length wear area" field) |
Lower the load hook as far down as possible.
This facilitates the measuring of the wire rope.
Measure the distance of the "Rope position" from the fixed point of
the wire rope hoist.
This is the point at which the pronounced wear begins on the wire rope section.
The wire rope section with highest wear is usually located in the first fall, but it can also lie in other falls depending on usage. In this case, measure the distance of the "Rope position" starting from the fixed point of the wire rope hoist and around the reel on the bottom block.
Measure the "Total length wear area" from the start of the wire rope
section.
● This is the area where the wire rope section with the greatest wear is located. This is where broken wires are expected to appear first.
Start the wire rope test here.
See also “General Product Manual for ABUS Cranes”, section “Inspecting the wire rope”.
If it is determined that the maximum acceptable wear has not yet been reached at this point:
Inspect the entire remaining wire rope.
This section applies only to wire rope hoists with a twin hoist (not one but both wire rope ends are each wound onto their own cable drum) and wire rope hoists with a True Vertical hoist (not one but both wire rope ends are wound together onto a shared cable drum).
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Compensating sheave |
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These wire rope hoists wind the wire rope at both ends. The middle wire rope piece remains nearly motionless on the compensating sheave of the wire rope hoist. The compensating sheave functions as a fixed point and the two wire rope halves are considered two individual wire ropes.
The wear calculated by ABUControl applies to the first as well as the second wire rope half. Due to the symmetrical arrangement, the same wear is assumed for both wire rope halves.
Inspect the wire rope half both to the left of the compensating
sheave and to the right of the compensating sheave. The compensating sheave is
considered a fixed point.
ABUControl considers the wire rope on the compensating sheave as a fixed point. For this reason, the wear cannot be calculated here.
However, due to swinging of the load and marginal variations in rotation of the two cable drums, wear also occurs on the wire rope on the compensating sheave.
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Danger due to a suspended load falling! ABUControl cannot calculate the wear for the wire rope on the compensating sheave. Therefore, also examine the wire rope piece on the compensating sheave with extra care. |
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Compensating sheave | |
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Wire rope piece on the compensating sheave |
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Inspect the wire rope piece on the compensating sheave especially
carefully in addition to the rest of the wire rope.
If the wire rope has reached its maximum acceptable wear:
Replace the wire rope. See Replacing the wire rope as well as the
product manual of the wire rope hoist.
