Extrusion Line for Port Container Crane Wire Ropes

Extrusion Line for Port Container Crane Wire Ropes

The extrusion production line for port container crane wire ropes is a high-end wire rope deep-processing equipment specifically designed to meet the demands of high-intensity, high-frequency, and harsh working conditions in ports. The core process of this line involves melt extrusion to coat the surface of specialized port crane wire ropes (such as those for drums, hoisting, and traction) with a dense polymer protective layer (primarily high-wear-resistant PVC, PE, or specially modified nylon), forming plastic-coated wire ropes or coated wire ropes.
Core Purpose and Product Value:
Core Purpose: To provide ultimate protection for port crane wire ropes against the severe corrosion of the marine environment and intense mechanical wear, enabling safe, efficient, low-maintenance continuous operation.
Product Value:
Superior Corrosion Resistance: Effectively isolates salt spray and humid air, preventing internal corrosion of the wire rope, extending service life multiple times.
Exceptional Abrasion Resistance: The protective layer withstands repeated friction with sheaves and drums and reduces internal wear between wires.
Prevention of "Birdcaging": The plastic coating enhances the integrity of the wire rope, effectively suppressing "birdcaging" caused by shock loads or improper operation.
Operational Visibility: Bright colors (e.g., yellow, red) facilitate operator observation and inspector safety assessment.

Line Composition

Based on standard wire rope extrusion lines, this line is reinforced to handle the large diameter, high strength, and great length characteristics of port wire ropes. Its main components include:
1. High-Tonnage Active Pay-off Unit
Function: Supports large port wire rope reels weighing several tons to tens of tons and uses an active drive mode to achieve stable pay-off synchronized with the main line.
Key Feature: Equipped with precision torque motors or frequency conversion speed control to ensure constant tension during start-up, operation, and stopping of the massive wire rope, preventing any抖动 or damage.
2. High-Efficiency Pre-heating System
Function: Provides sufficient and uniform pre-heating for the thick wire rope.
Key Feature: Utilizes high-power induction heating or long-stroke hot air circulation ovens to ensure the wire rope core reaches the optimal adhesion temperature, thoroughly removing surface moisture and guaranteeing adhesion for the thick-walled coating.
3. Large Plastic Extruder
Function: The heart of the production line, requiring sufficient, stable, and uniformly plasticized melt to coat large-diameter wire ropes.
Key Feature: Employs an extruder with a large-diameter, high-torque screw to ensure melt quality at high output; an advanced temperature control system guarantees polymer material performance.
4. Heavy-Duty Crosshead Extrusion Die
Function: Achieves 360° uniform, gap-free coating of the wire rope with melt.
Key Feature: Specially designed flow channels ensure uniform melt discharge under high pressure and high flow rates, resulting in extremely high coating concentricity and no eccentricity.
5. Multi-Stage Cooling Trough
Function: Provides gradient cooling and setting for the thick-walled coating.
Key Feature: Uses a long-distance, multi-stage temperature-controlled cooling trough. By adjusting the water temperature in each stage (from high to low), the plastic layer crystallizes and solidifies slowly from the inside out, avoiding internal stress, sink marks, or deformation, and ensuring a dense, round coating.
6. High-Traction Force Caterpillar Puller
Function: Provides huge and stable pulling force to overcome the operating resistance of the entire system.
Key Feature: Features a multi-caterpillar, long clamping surface design, driven by hydraulic or servo motors, delivering powerful traction while avoiding damage to the coating surface. Offers high-precision, variable speed control.
7. High-Capacity Reel Take-up Unit
Function: Winds the finished plastic-coated wire rope, which can be thousands of meters long, neatly and tightly onto large reels.
Key Feature: Possesses high tonnage load capacity, equipped with a precision traverser and constant tension control system to ensure winding quality, facilitating transportation and subsequent installation.
8. Fully Automated Integrated Control System
Function: The brain of the production line.
Key Feature: Based on industrial computers and PLCs, it achieves synchronized control of the entire line, real-time monitoring of parameters (temperature, tension, speed, length), fault diagnosis and alarm, and stores process recipes for different product specifications, enabling one-touch production.

Extrusion Line for Port Container 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 Port Container Crane Wire Ropes Application

The plastic-coated wire ropes produced by this line are critical safety components for modern port container cranes, primarily used in:
1. Quayside Container Cranes (Quay Cranes)
Application Areas: Hoist ropes, trolley traction ropes.
Advantages Demonstrated:
Long Service Life: Facing the direct marine corrosive environment, their lifespan far exceeds that of bare wire ropes, significantly reducing replacement frequency and downtime.
High Reliability: Excellent abrasion resistance suits the high-speed, high-frequency operation of quay cranes, reducing safety incidents caused by hazards like wire breaks.
Low Maintenance Cost: Reduces the workload of daily lubrication maintenance, significantly lowering overall operating costs.
2. Rubber-Tired Gantry Cranes (RTGs) / Rail-Mounted Gantry Cranes (RMGs)
Application Areas: Hoist ropes.
Advantages Demonstrated: Can adapt to potential oil stains and damp environments on the yard ground; bright colors aid ground personnel in observation and avoidance.
3. Gantry Cranes
Application Areas: Hoist ropes, luffing ropes.
Advantages Demonstrated: Their corrosion and wear resistance also apply to these universal port cranes, improving equipment availability.