An armor forming and processing apparatus for marine flexible tubular cables

Abstract

This invention provides an armoring forming apparatus for marine compliant cables, comprising: a cable-laying device for placing and guiding the cable into the armoring process; a positioning device for positioning the cable radially; and a cable sequentially passing through a skeleton layer armoring mechanism, a compression layer armoring mechanism, and a tensile layer armoring mechanism. The skeleton layer armoring mechanism plastically deforms and winds the steel strip around the outside of the cable to form a skeleton layer. The compression layer armoring mechanism and the tensile layer armoring mechanism are coaxially mounted with the skeleton layer armoring mechanism and connected to a drive system. The compression layer armoring mechanism winds the steel strip around the outside of the skeleton layer to form a compression layer, and the tensile layer armoring mechanism winds the steel strip around the outside of the compression layer to form a tensile layer. After armoring, the cable is guided to a take-up device by a traction device. This invention, by optimizing the equipment structure and workflow, achieves highly efficient cable armoring forming, significantly improving production efficiency and reducing production costs.

Description

Technical Field

[0001] This invention belongs to the field of armor winding technology, specifically relating to an armor forming and processing device for marine flexible tubular cables. Background Technology

[0002] With the rapid increase in energy consumption, the exploration and development of offshore oil and gas resources has become increasingly active. Marine pipelines and cables, as core equipment in deep-sea oil and gas extraction, are like the nerves and blood vessels of the offshore oil production system, maintaining the smooth operation of the entire extraction process. Among them, the importance of flexible marine cable armor, as a crucial component of cable protection, is self-evident. Flexible cable armor not only effectively resists external mechanical damage but also prevents seawater erosion and marine organism attachment, ensuring the stable laying of cables in complex seabed environments. Existing armor forming equipment is costly and has long maintenance cycles. It lacks dynamic control over the amount of plastic deformation during strip forming (such as Z-shaped and C-shaped section forming), easily leading to wave wrinkling defects. Furthermore, the transmission system of the processing equipment is inefficient and lacks synchronization. The transmission systems of the skeleton layer, compression layer, and tensile layer use independent drives, resulting in speed matching errors (such as the complex speed ratio design of the planetary gear system in the tensile layer), leading to pitch deviations in the armor layers. The lightweight and flexibility of flexible tubular armor makes submarine cables easier to lay and retrieve, reducing construction difficulty and costs, and further improving the economics and feasibility of offshore oil extraction. The armor structure is one of the key features that enables submarine cables to overcome the challenges of the deep-sea environment and transmit electrical energy safely and efficiently, significantly distinguishing them from terrestrial cables. Therefore, strengthening the research and application of flexible tubular armor in offshore oil production systems is of great significance for ensuring production safety and improving extraction efficiency. Summary of the Invention

[0003] The purpose of this invention is to overcome the above-mentioned problems and provide an armor forming and processing apparatus for marine flexible tubular cables.

[0004] The objective of this invention is achieved through the following technical solution:

[0005] An armoring forming and processing apparatus for a marine compliant cable includes: a cable-laying device for placing and guiding the cable into the armoring process; the cable passes through a positioning device to position its radial position; the cable sequentially passes through a skeleton layer armoring mechanism, a compression layer armoring mechanism, and a tensile layer armoring mechanism; the skeleton layer armoring mechanism plastically deforms and winds strip steel onto the outside of the cable to form a skeleton layer; the compression layer armoring mechanism and the tensile layer armoring mechanism are coaxially mounted with the skeleton layer armoring mechanism and are respectively connected to a drive system; the compression layer armoring mechanism winds strip steel onto the outside of the skeleton layer to form a compression layer; the tensile layer armoring mechanism winds strip steel onto the outside of the compression layer to form a tensile layer; a planetary gear system is installed on one side of the tensile layer armoring mechanism; and the armored cable is guided to a take-up device by a traction device.

[0006] Furthermore, the positioning mechanism includes two sets of adjustable rollers, which are mounted on a clamping plate via shafts, bushings, and bearings. The clamping plate is mounted on a bracket via adjusting bolts.

[0007] Furthermore, the skeleton layer armoring mechanism includes a auger cage, which contains five sets of circumferentially distributed wire feeding reels. During the process of the strip steel entering the wire feeding reel into the wire drawing die, the strip steel is gradually rolled into a Z-shape and self-locked with the already armored Z-shaped strip steel. Then, the self-locked strip steel is gradually wound onto the cable to complete the skeleton layer armoring process.

[0008] Furthermore, the pressure-resistant layer armoring mechanism includes a second winch, in which five sets of circumferentially distributed wire feeding reels are installed. During the process of the strip steel entering the wire feeding reel second and the wire drawing die second, the strip steel is gradually rolled into an S-shape and self-locked with the already armored S-shaped strip steel. Then, the self-locked strip steel is gradually wound onto the cable to complete the pressure-resistant layer armoring process.

[0009] Furthermore, the tensile layer armor mechanism includes a winch three, which contains three sets of circumferentially distributed wire feeding reels three, and the strip steel is gradually wound onto the cable to form a tensile layer.

[0010] Furthermore, the drive system includes three drive motors, which are connected to the wire feeding reels of the first, second, and third winches respectively through a gear transmission mechanism.

[0011] Furthermore, the planetary gear train structure includes a planetary gear carrier and a central gear. The central gear has teeth on its outside, and five evenly distributed planetary gears are installed between the central gear and the gear ring. The cable forming the tensile layer passes through the central gear. The planetary gear train structure adjusts the rotational speed and amplifies the torque, making the tensile layer more secure.

[0012] Furthermore, it also includes: an inner sheath forming device and an outer sheath forming device, which are used to coat the cable with inner and outer sheaths after the skeleton layer, compression layer and tensile layer armoring of the cable are completed, so as to improve the corrosion resistance and mechanical strength of the cable.

[0013] Furthermore, the installation angles of the first, second, and third cable reels are 78-82 degrees relative to the cable axis.

[0014] Furthermore, the take-up device includes a take-up drive, a take-up shaft frame, and a cable arrangement device, which neatly arranges the cable on the take-up reel.

[0015] The beneficial effects of this invention are as follows:

[0016] This invention optimizes the equipment structure and workflow, achieving highly efficient cable armor forming and processing. It can process more cables per unit time, thereby significantly improving production efficiency and reducing production costs.

[0017] The marine flexible cable armor forming and processing equipment of the present invention has shown significant advantages in terms of high-efficiency production, precise forming, flexible adaptation, structural stability, intelligent operation and energy saving and environmental protection, providing a high-efficiency, reliable and environmentally friendly processing device for the marine engineering field. Attached Figure Description

[0018] Appendix Figure 1 This is a schematic diagram of the structure of the present invention.

[0019] Appendix Figure 2 This is a schematic diagram of the planetary gear train mechanism of the present invention.

[0020] Appendix Figure 3 This is a schematic diagram of the positioning mechanism of the present invention.

[0021] Appendix Figure 4 It is attached Figure 3 AA sectional view.

[0022] Appendix Figure 5 This is a schematic diagram of the installation of the auger in the skeleton layer armor mechanism of the present invention.

[0023] Appendix Figure 6 This is a schematic diagram of the tensile layer armor mechanism of the present invention.

[0024] Appendix Figure 7 This is a schematic diagram illustrating the working principle of the present invention.

[0025] Appendix Figure 8 This is a schematic diagram of the structure of the skeleton layer armor mechanism, the compression layer armor mechanism, and the tensile layer armor mechanism of the present invention.

[0026] In the attached diagram: 1. Take-up device; 2. Traction device; 3. Tensile layer armor mechanism; 4. Compression layer armor mechanism; 5. Skeleton layer armor mechanism; 6. Positioning mechanism; 7. Pay-off device.

[0027] 31. Windlass, 32. Compactor layer after armoring, 33. Transmission mechanism, 34. Strip steel, 35. Tensile layer in armor, 36. Tensile layer cable reel, 37. Cable after armoring.

[0028] 51. Winch 1; 52. Cable feeder 1; 53. Wire paralleling die;

[0029] 61. Bracket; 62. Idler roller; 63. Clamping plate; 64. Shaft and bushing; 65. Bearing; 66. Adjusting bolt;

[0030] 81. Gear ring, 82. Planetary gear, 83. Planetary gear carrier, 84. Center gear. Detailed Implementation

[0031] The present invention will now be further described with reference to the accompanying drawings.

[0032] Example 1:

[0033] This invention provides an armor forming and processing apparatus for marine flexible tubular cables, as shown in the attached diagram. Figure 1 , 7 As shown, its components include: a take-up device 1, a traction wheel 2, a tensile layer armor mechanism 3, a compressive layer armor mechanism 4, a skeleton layer armor mechanism 5, a positioning mechanism 6, and a pay-off device 7.

[0034] The cable laying device 7 is used to place and guide the cable into the armoring process. The cable passes through the positioning device 6 to position the radial position of the cable. The cable passes sequentially through the skeleton layer armoring mechanism 5, the compression layer armoring mechanism 4, and the tensile layer armoring mechanism 3. The skeleton layer armoring mechanism plastically deforms the strip steel and winds it around the outside of the cable to form a skeleton layer. The compression layer armoring mechanism 4 and the tensile layer armoring mechanism 3 are coaxially installed with the skeleton layer armoring mechanism and are respectively connected to the drive system. The compression layer armoring mechanism 4 winds the strip steel around the outside of the skeleton layer to form a compression layer, and the tensile layer armoring mechanism 3 winds the strip steel around the outside of the compression layer to form a tensile layer. A planetary gear system 8 is installed on one side of the tensile layer armoring mechanism 3. After the cable is armored, it is led to the take-up device 1 by the traction device 2.

[0035] As attached Figure 3-4 As shown, the positioning mechanism 6 includes two sets of adjustable rollers 62. The rollers 62 are mounted on the clamping plate 63 via shafts, bushings 64, and bearings 65. The clamping plate 63 is mounted on the bracket 61 via adjusting bolts 66. The positioning mechanism 6 is located before the armoring mechanism of the skeleton layer, the compression layer, and the tensile layer.

[0036] The positioning mechanism 6 is used to clamp and guide the optical cable into the armoring mechanism. The roller group adopts an adjustable structure to accommodate cables of different diameters.

[0037] As attached Figure 5 , 8 As shown, the skeleton layer armoring mechanism 5 is used to plastically deform the strip steel and wind it around the outside of the optical cable to form a skeleton layer. It consists of a frame, on which a auger 51 is installed. Five circumferentially distributed wire feeding reels 52 are installed inside the auger 51. During the process of the strip steel entering the wire feeding reel 52 into the wire drawing die 53, the strip steel is gradually rolled into a Z-shape and self-locked with the Z-shaped strip steel that has been armored. Then the self-locked strip steel is gradually wound onto the cable to complete the skeleton layer armoring process.

[0038] The winch 51 tightly winds the steel strip onto the cable. Its dimensions are determined by the cable diameter and the required number of armor layers to ensure that each layer of steel strip is wound evenly and tightly. Inside the winch, the cable is rotated and advanced evenly, while the steel strip is precisely guided to the cable surface to form a tight armor layer. The paralleling die, located after the winch 51, tightly combines the multiple layers of armor steel strips together. Through the processing of the paralleling die, the gaps between the steel strips are minimized, thereby improving the mechanical strength and durability of the armored cable and ensuring the integrity and stability of the armor layer. Five sets of circumferentially distributed pay-off reels 52 are installed inside the winch 51. The installation angle of the pay-off reels 52 is arranged at a preset angle to the cable axis. After the steel strip enters the paralleling die from the pay-off reels, it is gradually rolled into a Z-shape and self-locks with the formed Z-shaped steel strip.

[0039] In this embodiment, the anti-compression layer armoring mechanism 4 is used to wind the strip steel to the outside of the skeleton layer to form an anti-compression layer. Its components include: a second auger, in which five sets of circumferentially distributed wire feeding reels are installed. During the process of the strip steel entering the wire feeding reel and the wire feeding die, the strip steel is gradually rolled into an S-shape and self-locked with the already armored S-shaped strip steel. Then, the self-locked strip steel is gradually wound onto the cable to complete the anti-compression layer armoring process.

[0040] The compression layer armor mechanism is similar in structure to the skeleton layer armor mechanism, but the strip steel cross-section is S-shaped, and the compression layer strip steel is wound and formed by the same arrangement of the auger and the wire feeding reel.

[0041] As attached Figure 6 As shown, the tensile layer armor mechanism 3 includes a winch 31, and three sets of circumferentially distributed wire reels 32 are installed inside the winch 31. The strip steel is gradually wound onto the cable to form a tensile layer.

[0042] Preferably, the wire feeding reel 52 includes a wire feeding frame and a wire feeding reel. The wire feeding reel is a set of supports with lifting screws, and is equipped with a tension control device to ensure that the steel strip or cable maintains constant tension during the wire feeding process, avoiding cable slack or breakage caused by uneven tension. By adjusting the lifting screws, it can adapt to cables of different diameters and lengths, improving the versatility and flexibility of the equipment. The wire feeding reel adopts a semi-tangential steel strip head design to ensure that the steel strip is stable and not easily broken during the wire feeding process. The rotation speed of the wire feeding reel can reach 200-500 rpm, and the efficient wire feeding speed provides a stable and continuous supply of raw materials for subsequent processes. The wire feeding reel is equipped with guide wheels and guide rods, which mainly guide the steel strip and adjust the wrapping angle of the steel strip to ensure that the steel strip can be wrapped flatly and neatly on the cable.

[0043] The strip has 5 heads and a helix angle of 7.26°.

[0044] The structures of feed reel 1, feed reel 2, and feed reel 3 are the same.

[0045] The pay-off reel achieves uniform distribution and tight winding of the steel strip by precisely controlling its rotation speed and winding angle. The merging die, located after the winding cage, is used to merge multiple layers of steel strip to ensure the integrity and stability of the armor layer.

[0046] In this embodiment, the traction device 2 typically consists of a set of traction wheels with a diameter of 2 meters or more. The traction wheels guide the armored cable to the take-up reel while maintaining the cable's stability and tension during transmission. By adjusting the speed and tension of the traction wheels, it is ensured that the cable does not become slack or overstretched during take-up.

[0047] The drive system described in this embodiment includes three drive motors, which are connected to the wire feeding reels of the first, second, and third winches respectively through a gear transmission mechanism.

[0048] The motor transmits power to the auger of the skeleton layer, compression layer and tensile layer armor mechanism through a gear transmission mechanism.

[0049] The gear transmission mechanism provides motion and power for the rotation of the winch, and it is mounted on a circular plate on the back of the wire feeding reel.

[0050] As attached Figure 2 As shown, the planetary gear train structure 8 has a planetary gear carrier 83 and a central gear 84. The central gear 84 has teeth on its outside. Five evenly distributed planetary gears 82 are installed between the central gear 84 and the gear ring 81. The cable forming the tensile layer passes through the central gear 84. The planetary gear train structure 8 adjusts the rotational speed and amplifies the torque, making the tensile layer more secure.

[0051] The take-up device described in this embodiment includes a take-up transmission device, a take-up shaft frame, and a cable arrangement device, which neatly arranges the armored cable on the take-up reel.

[0052] The cable take-up and cable laying device is the final process of the armoring machine. It consists of a take-up drive, a take-up spool, and a cable laying device. The take-up drive can be a separate drive or a machine-wide linkage to adapt to different production needs. The cable laying device is responsible for neatly arranging the cables on the take-up spool, avoiding crossing or overlapping. The cable laying device can be adjusted by mechanical or electric laying to ensure the neatness and tightness of the cables on the take-up spool.

[0053] Furthermore, the device of the present invention also includes: an inner sheath forming device and an outer sheath forming device, which are used to coat the cable with inner and outer sheaths after the skeleton layer, compression layer and tensile layer armor of the cable are completed, so as to improve the corrosion resistance and mechanical strength of the cable.

[0054] Example 2:

[0055] According to the armor forming and processing apparatus for marine flexible tubing described in Example 1, each step in the armor forming and processing of marine flexible tubing is closely connected, jointly ensuring the high quality and excellent performance of the tubing.

[0056] Processing technology of armored cable conduits:

[0057] Optical / electrical cable - skeleton layer winding - inner sheath layer wrapping - compression layer winding - tensile layer winding - outer sheath layer wrapping, etc.

[0058] Experimental procedure for the apparatus:

[0059] First, fiber / cable positioning utilizes a pay-off device and adjustable rollers or clamps for precise positioning, ensuring its stability during subsequent processing. This provides an accurate reference for the subsequent armor layer, preventing offset and twisting during processing. The required equipment includes a pay-off reel, guide rollers, and positioning clamps, which work together to ensure precise alignment of the fiber / cable's central axis with the rotation axis of the processing equipment.

[0060] Next, the precisely positioned optical / cable is fed into the winch cage, while the skeleton layer profile (such as Z-shaped steel strip) is wound around the optical / cable at a specific angle and tension under the drive of the drive device. The skeleton layer not only enhances the mechanical strength of the cable but also provides it with compressive strength. The equipment required for this process includes the winch cage, drive motor, and forming mold, which work together to ensure that the skeleton layer can be uniformly and tightly wrapped around the optical / cable, completing the positioning and winding forming of the skeleton layer profile.

[0061] Subsequently, the molten polymer material is heated and extruded into a cylindrical shape through an extruder, tightly covering the outer layer of the skeleton layer. The inner sheath layer serves as an insulator and protector, preventing external environmental corrosion of the cable's interior. The equipment required for this step includes an extruder, a die, and a cooling device, which ensure the uniformity and stability of the inner sheath layer, achieving the formation of the polymer cylindrical tube within the inner sheath layer.

[0062] Next, the positioning and winding of the compression layer profile and the tensile layer profile are completed. The tensile layer profile (such as rectangular cross-section steel strip) is wound around the compression layer at a specific helical angle and tension, forming a multi-layer structure. The tensile layer significantly improves the tensile strength and structural stiffness of the cable, ensuring its stability under tensile or torsional forces. Required equipment includes a winch, drive motor, and tension control device.

[0063] Finally, there is the outermost protective layer of the cable, the outer sheath. High-molecular polymer material is extruded through an extruder and coated onto the tensile layer, forming the final protective layer. The outer sheath not only isolates the cable from the external environment but also provides additional mechanical protection and abrasion resistance. The required equipment is similar to that for the inner sheath, including an extruder, molds, and cooling devices. Each step of the processing is closely interconnected, collectively forming the complete armor structure of the marine flexible cable, achieving the high-molecular polymer cylindrical forming of the outer sheath.

[0064] The equipment of this invention has a compact overall layout, with all components working in concert to achieve continuous armoring processing of optical and electrical cables, thereby improving production efficiency and processing quality.

[0065] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An armor forming and processing apparatus for marine flexible tubular cables, characterized in that, include: The cable laying device (7) is used to place and guide the cable into the armoring process. The cable passes through the positioning device (6) to position the radial position of the cable. The cable passes through the skeleton layer armoring mechanism (5), the compression layer armoring mechanism (4), and the tensile layer armoring mechanism (3) in sequence. The skeleton layer armoring mechanism plastically deforms the strip steel and winds it around the outside of the cable to form a skeleton layer. The compression layer armoring mechanism (4) and the tensile layer armoring mechanism (3) are coaxially installed with the skeleton layer armoring mechanism and are respectively connected to the drive system. The compression layer armoring mechanism (4) winds the strip steel around the outside of the skeleton layer to form a compression layer. The tensile layer armoring mechanism (3) winds the strip steel around the outside of the compression layer to form a tensile layer. A planetary gear system (8) is installed on one side of the tensile layer armoring mechanism (3). After the cable is armored, it is led to the take-up device (1) by the traction device (2). The tensile layer armor mechanism (3) includes a winch three (31), and three sets of circumferentially distributed wire reels three (32) are installed in the winch three (31). The strip steel is gradually wound onto the cable to form a tensile layer. The planetary gear system (8) includes a planetary gear carrier (83) and a central gear (84). The central gear (84) has teeth on its outside. Five evenly distributed planetary gears (82) are installed between the central gear (84) and the gear ring (81). The cable forming the tensile layer passes through the central gear (84). The planetary gear system (8) adjusts the rotation speed and amplifies the torque, making the tensile layer more secure.

2. The armor forming and processing apparatus for marine flexible tubular cables according to claim 1, characterized in that, The positioning device (6) includes two sets of adjustable rollers (62), which are mounted on a clamping plate (63) via shafts, bushings (64), and bearings (65). The clamping plate (63) is mounted on a bracket (61) via adjusting bolts (66).

3. The armor forming and processing apparatus for marine flexible tubular cables according to claim 1, characterized in that, The skeleton layer armoring mechanism (5) includes a auger (51), and five sets of circumferentially distributed wire feeding reels (52) are installed inside the auger (51). During the process of the strip steel entering the wire feeding reel (52) into the wire paralleling die (53), the strip steel is gradually rolled into a Z-shape and self-locked with the Z-shaped strip steel that has been armored. Then the self-locked strip steel is gradually wound onto the cable to complete the skeleton layer armoring process.

4. The armor forming and processing apparatus for marine flexible tubular cables according to claim 3, characterized in that, The pressure-resistant layer armoring mechanism (4) includes a second winch, in which five sets of evenly distributed wire feeding reels are installed. During the process of the strip steel entering the paralleling die from the wire feeding reels, the strip steel is gradually rolled into an S-shape and self-locked with the already armored S-shaped strip steel. Then the self-locked strip steel is gradually wound onto the cable to complete the pressure-resistant layer armoring process.

5. The armor forming and processing apparatus for marine flexible tubular cables according to claim 4, characterized in that, The drive system includes three drive motors, which are connected to the wire feeding reels of the first (51), the second (2), and the third (31) of the winch via gear transmission mechanisms.

6. The armor forming and processing apparatus for marine flexible tubular cables according to claim 1, characterized in that, Also includes: The inner sheath forming device and the outer sheath forming device are used to coat the cable with inner and outer sheaths after the skeleton layer and tensile layer armoring of the cable are completed, so as to improve the corrosion resistance and mechanical strength of the cable.

7. The armor forming and processing apparatus for marine flexible tubular cables according to claim 5, characterized in that, The installation angles of the first, second, and third cable reels are 78-82 degrees from the cable axis.

8. The armor forming and processing apparatus for marine flexible tubular cables according to claim 1, characterized in that, The take-up device includes a take-up drive, a take-up shaft frame, and a cable arrangement device, which neatly arranges the cable on the take-up reel.

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