The rope guide of the European wire rope electric hoist, as a key component, is prone to damage due to design, installation, operation, and environmental factors. The following are three typical situations and analysis of its susceptibility to damage:

1. Design or manufacturing defects

Material issue: If the rope guide is made of materials with insufficient strength or poor wear resistance (such as ordinary cast iron), it is prone to deformation or wear due to friction after long-term use. For example, traditional pig iron rope guides often break at screw holes due to their thin and narrow material.

Unreasonable structure: Poor matching between the rope guide and the drum (such as mismatched pitch and non-standard drum size) can cause the steel wire rope to deviate from the track, exacerbating friction. For example, if the diameter of the drum groove bottom does not match the design of the rope guide, it may cause severe wear on the drum groove.

Case: A certain brand of 3-ton electric hoist has difficulty adjusting the gap after the installation of the rope guide due to inconsistent processing depth between the middle and both ends of the drum, which makes it easy to get stuck and damaged during operation.

2. Improper installation

Axis deviation: The guide rope is not aligned with the axis of the drum, resulting in deflection and force during operation, causing the guide rope to break laterally. For example, failure to ensure that the rope guide is perpendicular to the drum during installation may cause the wire rope to jump or the rope guide to break.

Improper gap adjustment: If the gap between the rope guide and the drum is too large (the steel wire rope is prone to detach from the track) or too small (the steel wire rope is compressed), it will accelerate wear and tear. For example, a small gap may cause friction and heat generation between the steel wire rope and the rope guide, reducing its service life.

Operation example: Failure to conduct a no-load test run after the first installation, and failure to observe the arrangement of the steel wire rope, may result in rapid damage to the rope guide during formal use.

3. Problems encountered during use

Overloading operation: Long term overloading causes excessive force on the rope guide, accelerating fatigue damage. For example, if the rated lifting capacity of an electric hoist is 5 tons, but it actually lifts 6 tons of heavy objects for a long time, the rope guide may break due to overload.

Improper operation:

Diagonal pulling and lifting: Lateral squeezing force is generated between the steel wire rope and the rope guide, causing displacement of the rope guide or misalignment of the limit screw, resulting in premature or delayed action of the upward limit. For example, when inclined at a 30 degree angle, the lateral force on the rope guide may increase by 50%, making it highly susceptible to damage.

Frequent clicking and emergency stop: The impact load causes the rope guide to break. For example, during an emergency stop, the steel wire rope may suddenly loosen, and when restarted, the rope guide may break due to a sudden change in tension.

Insufficient lubrication: The friction area between the rope guide and the steel wire rope is short of oil, which exacerbates wear. For example, not regularly applying high-temperature resistant grease (such as lithium based grease) may cause the rope guide to become stuck or worn in high-temperature environments.

Abnormal wire rope: The wire rope is broken, corroded, or deformed, resulting in a rough surface and scratching of the rope guide. For example, a broken wire rope may cut the rope guide like a blade, causing it to quickly fail.

Poor environment: High temperature, dust, and humid environment can cause corrosion or jamming of the rope guide. For example, in a dusty environment, the rope guide may not run smoothly due to impurities entering the gap and ultimately be damaged.

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