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Wire Rope

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How do I calculate the dia of wire rope for aerial ropeway of 1 ton capacity ?

I am designing a aerial ropeway. Somebody please help me with the design calculations for the wire rope to be used.

The tension on a highline (aerial ropeway) is dependent on the sag consideration of the system. The smaller the sag, the more tension force will be on the highline. However, too much sag will make it more difficult to move a load from one end of the highline to the other end. Normally a sag equal to 2% of the span of the highline is used. Thus the tension on the highline is:

T = P/(2 sinA)

Where:

T = the tension on the highline

P = the load

A = the angle the rope makes with the horizontal when the load is at the middle of the highline

For a 2% sag:

tanA = 0.02L/0.5L = 0.04

But for small angles, the sine of the angle is approximately equal to the tangent of the angle. Hence for a 1ton (2200lbs) load, the tension on the highline is:

T =2200/(2 x 0.04) = 27500 lbs

Wire ropes are normally rated at their breaking strength. So if you consider a factor of safety of 5, the breaking strength of the wire rope that you need should be;

T' = 27500 x 5 = 137500 lbs. Thus select a wire rope diameter which has a breaking strength of not less than this.

There are other factors that must be considered in selecting the wire rope to be used.

a. Construction.
Wire ropes made of lesser number of wire strands are normally stronger than those with more wire strands of the same diameter but are less flexible. Since a trolley would be running on the highline, it would be preferred to use the more flexible wire rope construction like a 6 x 37 so that the wire rope will not kink even if the diameter of the sheaves of the trolley are smaller. Sheaves with diameter of 16 times the diameter of the wire rope can be used for a 6x37 construction but for a 6x19 wire rope construction, the sheaves should at least be 21 times the diameter of the wire rope.
b. Core type
Wire ropes with independent wire rope core are stronger than those with fiber core, but cost more.
c. Type of wire material
High grade plow steel (HGPS) wire ropes are stronger than ordinary improved plow steel (IPS) wire ropes.
d. Lay
The abrasion resistance of lang lay wire ropes are better than the regular lay because of the longer crown of wire strands where the sheaves bear on.

Find Wire Rope On eBay Below:

HIGH QUALITY WIRE ROPE CUTTER 24
HIGH QUALITY WIRE ROPE CUTTER 24
$175.00
KNIPEX Tools 95 62 160 Wire Rope Cutters with Opening Lock and Spring 6 Inch
KNIPEX Tools 95 62 160 Wire Rope Cutters with Opening Lock and Spring 6 Inch
$70.76
Crosby G 450 1010211 Wire Rope Steel Clip 7 8 In Clamp
Crosby G 450 1010211 Wire Rope Steel Clip 7 8 In Clamp
$10.00
Steel U bolt Clip 7 8 In Wire Rope Clamp
Steel U bolt Clip 7 8 In Wire Rope Clamp
$10.00
Crosby G 450 1010195 Red u bolt Clip 3 4 In Wire Rope Clamp
Crosby G 450 1010195 Red u bolt Clip 3 4 In Wire Rope Clamp
$10.00
Crosby G 450 1010051 Red u bolt Clip 1 4 In Wire Rope Clamp
Crosby G 450 1010051 Red u bolt Clip 1 4 In Wire Rope Clamp
$10.00
Crosby Red u bolt G 450 1010275 Steel Clip 1 1 4 In Wire Rope Clamp
Crosby Red u bolt G 450 1010275 Steel Clip 1 1 4 In Wire Rope Clamp
$10.00
TSUNODA King TTC Wire rope cutter WC 150 New
TSUNODA King TTC Wire rope cutter WC 150 New
$15.48
Stainless Steel 304 HookEye Turnbuckle Wire Rope Tension Tighten Rope Craft
Stainless Steel 304 HookEye Turnbuckle Wire Rope Tension Tighten Rope Craft
$2.00
Cable Pulling Swivel 5 Ton Wire Line Rope 11000 LBS BALL BEARING SWIVEL
Cable Pulling Swivel 5 Ton Wire Line Rope 11000 LBS BALL BEARING SWIVEL
$45.00
36 Swaging Tool Two Hand Swager for 3 8 Wire Rope and Cable
36 Swaging Tool Two Hand Swager for 3 8 Wire Rope and Cable
$92.99
T 516D Tirfor Wire Rope Hoist T516D Cable Hoist come a long
T 516D Tirfor Wire Rope Hoist T516D Cable Hoist come a long
$603.59
Knipex 95 61 190 Wire Rope Cutter Shears Plastic Grip
Knipex 95 61 190 Wire Rope Cutter Shears Plastic Grip
$69.96
Knipex 95 62 190 Wire Rope Cutters Shears MultiGrip
Knipex 95 62 190 Wire Rope Cutters Shears MultiGrip
$71.54
M15 15mm Silver Swivel Stainless Steel 304 Wire Rope Pulley Block Set of 10
M15 15mm Silver Swivel Stainless Steel 304 Wire Rope Pulley Block Set of 10
$18.05
Brand New Knipex Tools 95 62 190 Wire Rope Cutters
Brand New Knipex Tools 95 62 190 Wire Rope Cutters
$68.70
IWISS Wire Crimpers Rope Crimping Hand Swage Tool For Copper Aluminum Loop Stop
IWISS Wire Crimpers Rope Crimping Hand Swage Tool For Copper Aluminum Loop Stop
$50.91
HK Porter 0390MTN 36 Shear Type Cable Cutter for Wire Rope up to 5 8
HK Porter 0390MTN 36 Shear Type Cable Cutter for Wire Rope up to 5 8
$229.95
Crosby Clips 1010051 Wire Rope Clip 1 4 NWB
Crosby Clips 1010051 Wire Rope Clip 1 4 NWB
$4.99
VORCOOL 32mm Swivel Stainless Steel Wire Rope Single sheaved Pulley Roller
VORCOOL 32mm Swivel Stainless Steel Wire Rope Single sheaved Pulley Roller
$12.19
Pell Morse Starrett Model W Hydrashear 3 4 Hydraulic Jack Wire Rope Cutter
Pell Morse Starrett Model W Hydrashear 3 4 Hydraulic Jack Wire Rope Cutter
$179.99
Gedore 2788799 8320 200 JL Wire rope cutter
Gedore 2788799 8320 200 JL Wire rope cutter
$144.34
Durable M25 25mm Swivel Stainless Steel 304 Double Wire Rope Pulley Block
Durable M25 25mm Swivel Stainless Steel 304 Double Wire Rope Pulley Block
$10.05
5Pieces M6 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
5Pieces M6 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
$23.92
3 8 Wire Rope clamps Galvanized 20
3 8 Wire Rope clamps Galvanized 20
$29.00
25Pcs M5 124cm Hook  Eye Turnbuckle Wire Rope Tension 304 Stainless Steel
25Pcs M5 124cm Hook Eye Turnbuckle Wire Rope Tension 304 Stainless Steel
$35.63
M6 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
M6 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
$7.74
M10 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
M10 304 Stainless Steel Closed Body Jaw Turnbuckle Wire Rope Tension
$11.84
Knipex Tools 95 62 190 T BKA 7 1 2 Wire Rope Cutters
Knipex Tools 95 62 190 T BKA 7 1 2 Wire Rope Cutters
$93.14
Knipex 95 62 190 Wire Rope Cutters
Knipex 95 62 190 Wire Rope Cutters
$56.99
IWISS IWS 1608M Crimping Tool for Wire Rope Swage Up to 1 8  Wire Rope Cutter
IWISS IWS 1608M Crimping Tool for Wire Rope Swage Up to 1 8 Wire Rope Cutter
$15.00
Durable M32 30mm Swivel Stainless Steel 304 Double Wire Rope Pulley Block
Durable M32 30mm Swivel Stainless Steel 304 Double Wire Rope Pulley Block
$9.74
M10 304 Stainless Steel Closed Body Jaw Jaw Turnbuckle Wire Rope Tension
M10 304 Stainless Steel Closed Body Jaw Jaw Turnbuckle Wire Rope Tension
$12.69
ENERPAC WC 910 HAMMERBLOW WIRE ROPE CUTTER SIZE B 1 1 16 WIE ROPE NEW
ENERPAC WC 910 HAMMERBLOW WIRE ROPE CUTTER SIZE B 1 1 16 WIE ROPE NEW
$400.00
ENERPAC WC 920 HAMMERBLOW WIRE ROPE CUTTER SIZE B 1 1 2 WIRE ROPE NEW
ENERPAC WC 920 HAMMERBLOW WIRE ROPE CUTTER SIZE B 1 1 2 WIRE ROPE NEW
$500.00
Slingco Cable Pulling Swivel Wire Line Rope 8000 lb 25249
Slingco Cable Pulling Swivel Wire Line Rope 8000 lb 25249
$120.00
Campbell Chain Wire Rope Thimble Stainless Steel 1 16 1 8 Pack of 10
Campbell Chain Wire Rope Thimble Stainless Steel 1 16 1 8 Pack of 10
$10.30
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool HO
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool HO
$9.65
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool BS
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool BS
$9.86
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool RD
Reinforcement Construction Winding Tool Wire Knotting Pliers Wire Rope Tool RD
$9.79


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