The film was created as a teaching aid for vocational school students. The film describes in detail the technological process of producing steel ropes, metal cord and reinforcement for conveyor belts.
A bridge over a river supported by steel cables.
A ship with a mast reinforced with steel cables.
A drilling rig that lowers drills using steel cables.
An excavator that uses cables in its construction.
A port crane that lifts cargo using, among other things, steel cables.
An overhead crane in a metallurgical plant.
Steel cables consist of a large number of wires twisted into strands.
A cartoon showing different types of wire weaves.
Weave samples.
Cables can be round, flat, semi-closed, closed, and shaped.
Special shaped wire is used in closed cables.
Cross-section samples.
Types of shaped cross-sections.
Cores are used in cables to provide reliable support for the strands and the required properties.
Samples of materials used to make cores.
A cartoon explaining the importance and types of wire contact when weaving cables.
The twist of strands and ropes has 2 directions: right (Z) and left (S).
In ropes with double one-sided twist, the direction of strands and ropes is the same.
In ropes with double cross twist, they are different.
For the production of strands, special rope wire is used, which is obtained from carbon steel.
Thermomechanical processing of wire in a furnace.
This is followed by the removal of scale in a pickling bath, rinsing in water, and application of a lubricating layer of borax.
After drying, the heat-treated wire is wound on process reels.
Then, to obtain a given diameter and strengthen the metal, the wire is subjected to multiple drawing in special devices - dies.
Wire with a diameter of more than 0.6 mm is obtained by dry drawing, less - by wet drawing.
The drawing process is carried out in special emulsion solutions.
Spool with rope.
Winding of wires on charging reels.
Twisting of strands.
Twisting of ropes.
Application of preservative grease.
Testing of ropes.
Packing of spools with ropes.
Marking of ropes.
Spinning machine.
Basket spinning machine.
Cigar spinning machine.
The division depends on the device of the twisting mechanism.
The twisting mechanism of the cigar spinning machine consists of hollow pipes, inside which there are carriages and installations of charging spools with wire.
Installation of a charging spool with wire.
Connection of the ends of the wire during loading of the machine using an electric butt welding machine.
Cleaning of the weld seam.
Distribution templates designed for the correct formation of the strand.
Samples of templates.
Crimping dies in which the actual formation of strands and their crimping takes place.
Samples of dies.
Lubrication of strands at the entrance of the wire into the die to improve the operational and anti-corrosion properties of the rope.
Straightening of ropes in crimping rollers, subjecting them to repeated bending.
Pull-out mechanism.
Winding of the rope on the charging spool of the rope-twisting machine.
Control panel for the twisting process.
The twisting mechanism of the basket spinning machine.
It is a rotor consisting of a shaft and supporting disks.
Straightening of ropes in the pressing rollers of the basket spinning machine.
A drawing comparing the basket and cigar rope twisting machines for twisting ropes from strands.
Wire, Strands, Ropes, Rope twisting
Basket and cigar rope-twisting machines.
They are similar in design to spinning machines.
The difference is the large size of the main units.
The core is fed into the machine from the end part along the twist axis.
The strands for the rope must be made on the same machine with the same twist pitch.
The charging reel is installed so that the strand is wound from the top.
Before twisting, the strands are passed through the rollers of the preforming device.
As a result, the strand acquires a spiral shape, which ensures that the rope does not unwind.
Rope straightening to relieve internal stress.
After the drawing mechanism, the rope passes through a bath with grease and is wound in tight rows on a wooden drum.
Fencing the rotation zone of the rotors of the rope-twisting mechanisms with a metal grid.
Cars drive on the road.
Reinforcement for strengthening the tires of car wheels.
Metal cord is a twist of the thinnest, especially strong wires.
Brass plating of wire on galvanic units for high strength of the bond between wire and rubber.
The wire from the unwinding device passes through a heating furnace, a bath with molten lead, burning charcoal, is washed in hot water, processed in acid to remove scale and subjected to bipolar etching in an alkaline solution.
A layer of copper is applied to the surface of the wire in a galvanic copper plating bath.
A layer of zinc is applied in a galvanizing bath.
Wire with a copper-zinc coating is subjected to thermal diffusion treatment in an electric contact unit and wound on reels.
After drawing the wire, two-, three-, four- and five-wire strands are made from it, from which metal cord is twisted.
Samples of metal cord sections.
Rope-twisting machines for the production of metal cord.
Twisting devices.
Distribution template.
Crimping dies.
Straightening device.
Extraction mechanism.
Winding device.
Control device of the machine for twisting metal cord.
Laboratory for quality control of metal cord.
Rubberized samples of metal cord are tested on a tensile testing machine.
The elemental composition of the brass coating is analyzed on an atomic absorption spectrophotometer.
Packaging of metal cord.
Metal cord is transported and stored in tightly closed metal barrels.
Manufacture of metal cord from brass-plated wire.
After rubberizing, durable conveyor belts for the coal and mining industries are obtained from it.
Sections of a conveyor belt, on which strands of brass-plated wire are visible.
Conveyor for transporting iron ore.
The process of rubberizing metal cord, which begins the production of tires.
Tire production line.
Tires on an airplane chassis.
A building with a monolithic roof made of concrete reinforced with prestressed ropes.
Ropes that hold up a multi-ton bridge structure.
The Ostankino TV tower, in the construction of which ropes were also used.
Ropes, Metal cord, Metal cable
Ostankino TV Tower.