Extrusion Line for Construction Tower Crane Wire Ropes

Extrusion Line for Construction Tower Crane Wire Ropes

The extrusion production line for construction tower crane wire ropes is a specialized wire rope deep-processing equipment designed for tower crane working conditions. This production line employs a precision extrusion process to coat the surface of specialized tower crane wire ropes (such as hoist ropes and luffing ropes) with a tough plastic layer (primarily UV-resistant and aging-resistant PVC or PE), producing plastic-coated wire ropes.
Core Purpose and Product Value:
Core Purpose: To enhance the durability and safety of tower crane wire ropes, enabling them to withstand harsh outdoor construction environments, reduce failures, and ensure construction progress and safety.
Product Value:
Super Weather Resistance: Special plastic formulations effectively resist UV radiation, rain erosion, and temperature fluctuations, preventing premature aging and embrittlement of the coating.
Excellent Abrasion Resistance: The protective layer reduces wear between the wire rope and sheaves or drums, particularly minimizing abrasive wear in dusty elevated environments.
Corrosion Prevention: Effectively isolates rain and moist air, preventing internal corrosion of the wire rope and extending its service life.
Safety Identification: The bright coating color (often yellow or red) is highly visible against aerial backgrounds, facilitating operator observation and remote monitoring of the wire rope's condition by ground safety inspectors.

Line Composition

Optimized for the characteristics of tower crane wire ropes – long length, weather resistance requirements, and high reliability – the main components include:
1. High-Capacity Pay-off Unit
Function: Supports and unwinds large tower crane wire rope reels, which can be hundreds or even thousands of meters long, ensuring smooth pay-off.
Key Feature: Equipped with a reliable tension braking system to maintain stable tension during long-distance unwinding, preventing tangling and knotting.
2. Pre-heating and Cleaning System
Function: Pre-heats and cleans the wire rope surface.
Key Feature: Combines pre-heating with physical cleaning (e.g., brushes, air blowers) to ensure removal of surface oxide layers, moisture, and oil stains, providing an ideal substrate for coating and guaranteeing adhesion.
3. Specialized Plastic Extruder
Function: Plasticizes and conveys weather-resistant plastic.
Key Feature: Utilizes a screw optimized for weather-resistant plastic compounds, with precise temperature control ensuring good plasticization and stable performance.
4. Precision Extrusion Die
Function: Achieves uniform coating of the plastic layer.
Key Feature: High-precision die ensures uniform coating thickness and high concentricity, avoiding premature localized wear due to eccentricity.
5. Multi-Stage Temperature-Controlled Cooling Trough
Function: Provides sufficient and gradual cooling and setting for the coating.
Key Feature: Segmented control of cooling water temperature enables gradient cooling, ensuring a dense internal structure in the plastic layer, eliminating internal stress, and preventing deformation and shrinkage.
6. High-Synchronization Puller
Function: Provides stable pulling force and precisely controls the production line speed.
Key Feature: A robust caterpillar puller strictly synchronized with the take-up speed ensures stable product diameter and smooth overall line operation.
7. High-Torque Take-up Unit
Function: Winds the finished plastic-coated wire rope neatly onto large reels.
Key Feature: High-torque design, coupled with a precision traverser, achieves neat and tight winding, facilitating transportation and on-site installation.
8. Intelligent Control System
Function: Monitors and coordinates the entire process.
Key Feature: Integratively controls all process parameters, features automatic length measurement, and fault alarm functions, ensuring process stability and product consistency.

Extrusion Line for Construction Tower Crane Wire Ropes Datasheet

Model	30	40	50	60	70	80	90
Screw Diameter (mm)	φ30	φ40	φ50	φ60	φ70	φ80	φ90
Screw L/D Ratio	25:1	25:1	26:1	26:1	26:1	26:1	26:1
Extrusion Amount (kg/hr)	25	40	70	100	140	200	250
Outlet Wire (mm)	0.2-1	0.4-3	0.8-5	1-8	2-15	3-25	5-35
Total Power (KW)	18	20	25	33	40	55	63
Traction Power (KW)	2.2	2.2	4	4	4	5.5	5.5
Production Speed (m/min (Max.))	600	600	600	500	500	300	300
Take-up Spool (mm)	φ200-400	φ300-500	φ400-630	φ400-630	φ500-630	φ800-1000	φ1000-1250

Extrusion Line for Construction Tower Crane Wire Ropes Application

The plastic-coated wire ropes produced by this line are critical safety components for tower cranes used in modern high-rise construction, primarily applied in:
1. Hoisting Mechanism
Application Area: Main hoist ropes, used for lifting loads.
Advantages Demonstrated:
Long Service Life: The wear and corrosion resistance characteristics result in a lifespan far exceeding that of bare wire ropes in harsh outdoor site conditions, reducing replacement frequency and costs.
High Reliability: Excellent weather resistance ensures stable wire rope performance throughout the project cycle, reducing unexpected downtime caused by wire rope issues.
Safety Visibility: The bright color facilitates the crane operator's observation of the wire rope's operation and spooling during aerial work, and aids safety monitoring by ground personnel.
2. Luffing Mechanism
Application Area: Trolley luffing ropes, controlling the movement of the trolley along the jib.
Advantages Demonstrated: The smooth plastic coating reduces friction with the sheave group, resulting in smoother operation, less wear, and ensuring steady and precise luffing.