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The Zigzag Groove(Lebus groove) is a form of rope groove specifically designed for the multi-layer winding of wire ropes, which is widely used in mechanical equipment such as lifting equipment, winches, and hoists. Its unique design can effectively solve problems such as uneven winding and severe wear of the wire rope on the drum, significantly improving the safety and service life of the equipment. Since this type of rope groove remains parallel to the end face of the flange in most sections of the circumferential direction of the drum, and only intersects with the end face of the flange in a very small section, the rope groove will inevitably show a zigzag phenomenon, hence the name "zigzag groove". As it originated in the United States and was invented by Mr. Frank.L.Lebus, the founder of Lebus International Inc. in the United States, this type of rope groove is generally called "Lebus Grooves" abroad, that is, the Lebus groove.

 

I. Technical Origin and Development History

1. 1900s: American engineer Frank L. Lebus discovered the problem of wire rope wear caused by traditional grooves, initiating his research and development.

2. 1937: Lebus International was established, pioneering the new single zigzag groove technology.

3. 1950: Upgraded to a double zigzag groove plus a deflection compensator, establishing modern technical standards.

4. 1960s: Global layout, with the technology covering nine major fields such as petroleum, mining, construction, and the marine industry.

II. Core Technical Characteristics

1. Groove Structure:

l Double zigzag groove type (alternating between 80% straight grooves and 20% inclined grooves)

l Patented sleeve design (carbon steel, stainless steel, and composite materials are optional)

l Flat flange + first layer spacer structure

2. Boundaries of Performance Parameters:

| Index | Maximum Value | Typical Application Cases |

|--------------|---------------------|------------------------------------------------|

| Wire Rope Diameter | φ100mm | 500-ton marine crane in Japan (φ94mm) |

| Number of Winding Layers | 50 layers | Deep-sea winch in the UK (48 layers) |

| Linear Velocity | 190m/min | Hydrological winch in South Africa |

| Rope Capacity | 10,000m | Cable coiling device in Japan (φ44mm) |

| Drum Size | φ5m×4.5m (flange) | The same as the cable device in Japan |

III. Differences in Application Fields

1. Advantageous Fields: Marine engineering (83%), petroleum drilling (76%), special hoisting (68%)

2. Restricted Fields: Hydropower projects (less than 5% in Europe and America, 12% in Japan), mainly affected by the competition of hydraulic hoists.

IV. Key Technical Specifications (Global Standards)

1. Installation Reference: Flange perpendicularity error ≤ 0.1°

2. Tension Control:

l German Standard: ≥ 2% of the breaking tensile force

l Japanese and American Standards: ≥ 1.7% of the breaking tensile force

3. Deflection Management:

l Ideal Range: 0.25° - 1.25°

l Compensator Activation Threshold: > 1.5°

l Minimum Standard: German standard 0.5°/ Japanese and American standard 0.25°

V. Modern Technical Extensions

1. Composite Drum Technology: The glass fiber sleeve achieves a disassembly and assembly life of more than 6,000 times.

2. Intelligent Monitoring System: Integrated with real-time feedback devices for tension and deflection.

3. Application of Supermaterials: The nano-coating reduces the friction coefficient by 37%.