Study on Abnormal Winding Behaviors of Hoisting Steel Wire Rope in Ultra-Deep Vertical Shaft

During multi-layer winding of hoisting steel wire ropes for ultra-deep vertical shafts on double broken-line drums, abnormal winding behaviors such as rope interlocking, rope jumping and disordered rope arrangement may occur, accelerating abrasion and wire breakage, reducing load-bearing capacity and service life, and compromising operational safety. A dynamic rope-jumping discrimination approach considering transverse-vibration-induced fleet-angle variation was developed and evaluated through field tests. Meanwhile, based on the spatial trajectory model of multi-layer wound hoisting steel wire ropes and a quantitative criterion for rope interlocking, the effects of key drum structural parameters on rope interlocking were investigated. Results show that the broken-line zone is the main high-risk region for rope jumping, with the rightmost position of the third layer after the second-to-third-layer transition being the most critical location. Transverse rope vibration increases the fleet angle, and rope jumping occurs when the critical threshold is exceeded. At the three representative winding positions, the relative errors between the calculated and measured fleet angles are below 7.0%, and the predicted high-risk rope-jumping location is consistent with the field observation, providing field-based support for the model under the examined operating condition. Rope-interlocking risk is significantly higher in the broken-line zone and increases with larger fleet angles, smaller rope groove clearance coefficients and larger drum-to-rope diameter ratios.