A fiber variable diameter cable and method of manufacturing the same

Abstract

This invention discloses a fiber variable diameter cable and its manufacturing method, comprising a cable body, the cable body including a core and a sheath, the core including a thick rope portion, a variable diameter portion, and a thin rope portion, the core being composed of several sub-ropes. The sub-ropes include thick and thin ropes; the thick rope portion is composed of all sub-ropes arranged in parallel; the number of sub-ropes in the variable diameter portion gradually decreases as the cable's variable diameter length increases; the thin rope portion is composed of several sub-ropes arranged in parallel; the sheath is woven around the outside of the core. The cable is designed as a gradient cable structure, with one end using a thick rope design to ensure sufficient strength and load-bearing capacity; the other end uses a thin rope design, facilitating winding and fixing using equipment such as winches, while significantly saving space. The intermediate transition section achieves a smooth transition from thick to thin by optimizing the sub-rope arrangement and weaving technology, avoiding stress concentration and abrupt strength changes.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a fiber variable diameter cable and its manufacturing method. Background Technology

[0002] In marine engineering, shipbuilding, and other fields, cables play a crucial role as important connecting and load-bearing components. Traditional cable designs often use fiber ropes of a single diameter, which has significant limitations in certain application scenarios. For example, in the FPSO (Floating Production Storage and Offloading) rendezvous and hoisting operations, cables need to simultaneously meet the requirements of high strength, ease of handling, and maximized space utilization.

[0003] Traditional thick ropes have high strength and can withstand large tensile forces, but when wound by equipment such as winches, their large diameter occupies a lot of space and is not easy to tightly arrange, resulting in reduced winch efficiency. While thin ropes are easy to wind and save space, their relatively low strength makes them unable to withstand large tensions on their own, limiting their application in heavy-duty operations.

[0004] To overcome this challenge, several solutions have emerged that attempt to improve cable performance by altering its structure or materials. However, these solutions mostly offer only limited improvements in strength or space utilization, often accompanied by significant increases in cost or manufacturing difficulty. Therefore, there is an urgent need for a new cable design that leverages the high strength of thicker ropes while utilizing the flexibility and space-saving advantages of thinner ropes. Summary of the Invention

[0005] The purpose of this invention is to provide a fiber variable diameter cable and its manufacturing method, thereby solving the problems mentioned in the background art.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution:

[0007] A method for manufacturing a fiber variable diameter cable, the method being as follows:

[0008] Step 1: Sub-rope making: The fibers are woven into 12-strand structural sub-ropes through processes such as yarn doubling, twisting, stranding, rope making, and / or coating. Multiple sub-ropes are woven in total.

[0009] Step 2: Rope core making: Place multiple sub-ropes parallel together to form the thick rope section. In order to achieve the diameter change effect, the sub-ropes are of different lengths. Insert the end of the shorter sub-rope into the longer sub-rope to connect the sub-ropes and thus make the rope core. After the sub-ropes are interwoven, the number of sub-ropes in the diameter change section will gradually decrease and gradually decrease to the number of sub-ropes required for the thin rope section.

[0010] Step 3: Sheath weaving: The rope core obtained in Step 2 is woven with a sheath on the outside using a horizontal weaving machine. The number of strands in the sheath can be any one of 96, 64, or 32. During the weaving process, the number of strands in the sheath gradually decreases to half of the original number, thus achieving overall coverage of the variable diameter section and the thin rope section.

[0011] Preferably, in step two, when changing the diameter, the end of one sub-rope is inserted into the middle of another sub-rope, with an insertion length of at least 10 times the diameter of the sub-rope. When one sub-rope is inserted into another sub-rope, the changing diameter section is formed. The number of sub-ropes in the changing diameter section of the rope core gradually decreases as the changing diameter length increases, and the interval between the decreases in sub-ropes is not less than 0.5m.

[0012] Preferably, in step two, the number of sub-strings in the thin rope section is no less than 3.

[0013] Preferably, the length of the variable diameter section should be at least 10m.

[0014] A fiber variable diameter cable includes a cable body, the cable body including a core and a sheath, the core including a plurality of sub-cords, the core being woven from the plurality of sub-cords, and each part having a different sub-cord arrangement, the core being divided into a thicker section, a variable diameter section and a thinner section, the thicker section being composed of all sub-cords arranged in parallel, the number of sub-cords in the variable diameter section gradually decreasing as the variable diameter length increases, the thinner section being composed of a plurality of sub-cords arranged in parallel, and the sheath being woven on the outside of the core.

[0015] Beneficial effects: The cable is designed as a tapered cable structure. One end of the tapered cable uses a thicker rope to ensure sufficient strength and load-bearing capacity, while the other end uses a thinner rope, facilitating winding and securing with equipment such as winches, and significantly saving space. The intermediate transition section achieves a smooth transition from thick to thin through optimized sub-rope arrangement and weaving technology, avoiding stress concentration and abrupt strength changes. This leverages the high strength of the thicker rope while utilizing the flexibility and space-saving properties of the thinner rope. The tapered cable is externally woven with a sheath, which completely wraps around the core, increasing the cable's strength and abrasion resistance, and preventing the interlocking sub-ropes from loosening during use. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of an embodiment;

[0017] Figure 2 This is a schematic diagram illustrating the thin rope portion of the cable body in Example 1;

[0018] Figure 3 This is a schematic diagram illustrating the thick rope portion of the cable body in Example 1;

[0019] Figure 4 This is a schematic diagram illustrating the structure of each sub-rope in an embodiment;

[0020] Figure 5 This is a schematic diagram illustrating the connection of a single sub-rope in an embodiment.

[0021] Figure 6 This is a schematic diagram illustrating the connection of two sub-ropes in an embodiment.

[0022] Figure 7 This is a schematic diagram illustrating the thick rope portion of the cable body in Embodiment 2;

[0023] Figure 8 This is a schematic diagram illustrating the thin rope portion of the cable body in Example 2.

[0024] Attached reference numerals: 1. Cable body; 2. Cable core; 3. Sheath; 4. Sub-rope. Detailed Implementation

[0025] The following description is merely a preferred embodiment of the present invention, and the scope of protection is not limited to this embodiment. All technical solutions falling within the scope of the present invention should be considered within the protection scope of the present invention. It should also be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the protection scope of the present invention.

[0026] Example 1, see Figure 1-6 As shown,

[0027] A method for manufacturing a fiber variable diameter cable, the method being as follows:

[0028] Step 1 Sub-rope making: HMPE fibers are woven into 12-strand sub-rope 4 through processes of spinning, twisting, stranding, rope making and / or coating. A total of 27 sub-ropes 4 are woven. The diameter of sub-rope 4 is 26mm and the twist pitch of sub-rope 4 is 155mm.

[0029] Step 2: Rope Core Construction: Place all sub-ropes 4 parallel together. The end where all sub-ropes 4 converge forms the thicker rope section. The nominal diameter of the core of the thicker rope section is 135mm, and the designed breaking strength is 1250t. To achieve the variable diameter effect, the sub-ropes 4 are woven into a structure of varying lengths. The ends of shorter sub-ropes 4 are inserted into longer sub-ropes 4 to connect them. Through the interlocking of the sub-ropes 4, the core 2 is finally formed. As the sub-ropes 4 interweave, the number of sub-ropes 4 in the variable diameter section gradually decreases until it reaches the number of sub-ropes 4 required for the thinner rope section. The number of sub-ropes 4 gradually decreases from 27 to 4 through interlocking. The nominal diameter of the core of the thinner rope section is 52mm, and the designed breaking strength is 180t.

[0030] In step two, since sub-rope 4 has a 12-strand structure and a hollow structure in the middle, when changing the diameter, the end of one sub-rope 4 is inserted into the middle of another sub-rope 4, with an insertion length of at least 500mm. When one sub-rope 4 is inserted into another sub-rope 4, the diameter-changing part is formed. In the diameter-changing part of the rope core 2, the number of sub-ropes 4 gradually decreases as the diameter-changing length increases, and the spacing of the reduction of sub-rope 4 is not less than 0.5m. The diameter-changing length of the rope core 2 is 15m.

[0031] Step 3: Sheath weaving: The rope core 2 obtained in Step 2 is woven with a horizontal braiding machine to form a sheath 3. The sheath 3 is 8mm thick. During the weaving of the diameter-changing section, the number of strands in the sheath 3 gradually decreases, so that the sheath 3 can adapt to the diameter-changing structure of the rope core 2, achieving overall coverage of the diameter-changing section and the thin rope section. By completely wrapping the rope core 2 with the sheath 3, not only can the strength and wear resistance of the diameter-changing cable be increased, but also the loosening of the various inserted sub-ropes 4 during the use of the rope core 2 can be prevented.

[0032] Example 2, see Figure 1 , 7 And as shown in 8

[0033] Step 1 Sub-rope making: HMPE fibers are woven into 12-strand sub-rope 4 through processes of spinning, twisting, stranding, rope making and / or coating. A total of 18 sub-ropes 4 are woven. The diameter of sub-rope 4 is 24mm and the twist pitch of sub-rope 4 is 360mm.

[0034] Step Two: Rope Core Construction: Place all sub-ropes 4 parallel together. The end where all sub-ropes 4 converge forms the thicker rope section. The nominal diameter of the core of the thicker rope section is 128mm, and the designed breaking strength is 1050t. To achieve the variable diameter effect, the sub-ropes 4 are woven into a structure of varying lengths. The ends of shorter sub-ropes 4 are inserted into longer sub-ropes 4 to connect them. Through the interlocking of the sub-ropes 4, the core 2 is finally formed. As the sub-ropes 4 interweave, the number of sub-ropes 4 in the variable diameter section gradually decreases until it reaches the number of sub-ropes 4 required for the thinner rope section. The number of sub-ropes 4 gradually decreases from 27 to 3 through interlocking. The nominal diameter of the core of the thinner rope section is 42mm, and the designed breaking strength is 120t.

[0035] In step two, since sub-rope 4 has a 12-strand structure and a hollow structure in the middle, when changing the diameter, the end of one sub-rope 4 is inserted into the middle of another sub-rope 4, with an insertion length of at least 500mm. When one sub-rope 4 is inserted into another sub-rope 4, the diameter-changing part is formed. In the diameter-changing part of the rope core 2, the number of sub-ropes 4 gradually decreases as the diameter-changing length increases, and the spacing of the reduction of sub-rope 4 is not less than 0.5m. The diameter-changing length of the rope core 2 is 15m.

[0036] Step 3: Sheath Weaving: The rope core 2 obtained in Step 2 is woven with a horizontal braiding machine to form a sheath 3. The sheath 3 is 10mm thick. During the weaving of the diameter-changing section, the number of strands in the sheath 3 gradually decreases, allowing the sheath 3 to adapt to the diameter-changing structure of the rope core 2. This achieves complete coverage of the diameter-changing section and the thin rope section. By completely wrapping the rope core 2 with the sheath 3, not only can the strength and abrasion resistance of the diameter-changing cable be increased, but it can also prevent the spliced ​​sub-ropes 4 from loosening during use.

[0037] A fiber variable diameter cable includes a cable body 1, the cable body 1 including a core 2 and a sheath 3, the core 2 including a plurality of sub-rods 4, each of the sub-rods 4 being woven from HMPE fibers, the core 2 being woven from a plurality of sub-rods 4, the core 2 being divided into a thick rope section, a variable diameter section and a thin rope section, the thick rope section being composed of all the sub-rods 4 arranged in parallel, the number of the sub-rods 4 in the variable diameter section gradually decreasing as the variable diameter length increases, the thin rope section being composed of a plurality of sub-rods 4 arranged in parallel, and the sheath 3 being woven on the outside of the core 2.

Claims

1. A method for manufacturing a fiber variable diameter cable, the method being as follows: Step 1 Sub-rope making: The fibers are woven into 12-strand structural sub-ropes (4) through processes such as yarn doubling, twisting, stranding, rope making and / or coating. Multiple sub-ropes (4) are woven in total. Step 2: Rope core making: Place multiple sub-ropes (4) together in parallel to form the thick rope section. In order to achieve the diameter change effect, the lengths of the sub-ropes (4) are different. Insert the end of the shorter sub-rope (4) into the longer sub-rope (4) to achieve the connection between the sub-ropes (4), thereby realizing the making of the rope core (2). After the sub-ropes (4) are interwoven with each other, the number of sub-ropes (4) in the diameter change section will gradually decrease and gradually decrease to the number of sub-ropes (4) required for the thin rope section. Step 3: Sheath weaving: The rope core (2) obtained in step 2 is woven into a sheath (3) on the outside by a horizontal weaving machine. The number of strands in the sheath (3) can be any one of 96 strands, 64 strands or 32 strands. During the weaving process, the number of strands in the sheath (3) gradually becomes half of the original number, so as to achieve overall coverage of the variable diameter part and the thin rope part.

2. The method of claim 1, wherein In step two, when the diameter is changed, the end of one sub-rope (4) is inserted into the middle of another sub-rope (4), and the insertion length is at least 10 times the diameter of the sub-rope (4). When one sub-rope (4) is inserted into another sub-rope (4), the diameter-changing part is formed. The number of sub-ropes (4) in the diameter-changing part of the rope core (2) gradually decreases as the diameter-changing length increases, and the spacing of the reduction of sub-ropes (4) is not less than 0.5m.

3. The method of claim 1, wherein In step two, the number of sub-strings (4) in the thin rope section shall not be less than 3.

4. The method of claim 2, wherein The length of the variable diameter section should be at least 10m.

5. A fiber variable diameter cable, comprising a cable body (1) obtained by the manufacturing method of any one of claims 1-4, wherein the cable body (1) comprises a core (2) and a sheath (3), the core (2) comprises a plurality of sub-rods (4), the core is woven from the plurality of sub-rods (4), the core (2) is divided into a thick rope portion, a variable diameter portion and a thin rope portion, the thick rope portion is composed of all the sub-rods (4) arranged in parallel, the number of the sub-rods (4) in the variable diameter portion gradually decreases as the variable diameter length increases, the thin rope portion is composed of the plurality of sub-rods (4) arranged in parallel, and the sheath (3) is woven on the outside of the core (2).

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